INTAKE MANIFOLD REMOVAL

PROCEDURE

1. PRECAUTION

   Note

   After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work Click here.

2. DISCHARGE FUEL SYSTEM PRESSURE

   Click here

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

   Note

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

   Click here

5. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

   Click here

6. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

   Click here

7. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

   Click here

8. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

   
   

   1. for LHD:

      
      

      1. 

         Disconnect the union to vacuum tube hose.

      2. Disengage the wire harness clamp.

   2. for RHD:

      
      

      1. Disconnect the union to check valve hose.

      2. Disengage the wire harness clamp.

   3. Disconnect the 2 vacuum hoses and vacuum switching valve assembly connector.

   4. Remove the bolt and vacuum switching valve assembly from the intake manifold.

9. DISCONNECT NO. 2 VENTILATION HOSE

   
   

   1. 

      Slide the clip and disconnect the No. 2 ventilation hose from the intake manifold.

10. DISCONNECT UNION TO VACUUM TUBE HOSE (for LHD)

    
    

    1. 

       Slide the clip and disconnect the union to vacuum tube hose from the intake manifold.

11. DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)

    
    

    1. 

       Slide the clip and disconnect the union to check valve hose from the intake manifold.

12. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

13. REMOVE FUEL DELIVERY PIPE

    Click here

14. REMOVE INTAKE MANIFOLD

    
    

    1. 

       Remove the 2 bolts and 2 wire harness clamp brackets from the intake manifold.

    2. 

       Slide the clip and disconnect the fuel vapor feed hose from the intake manifold.

    3. Disengage the 3 wire harness clamps.

    4. Disconnect the wire harness connector.

    5. Remove the bolt and wire harness clamp bracket.

    6. 

       Apply battery voltage to the terminals of the connector to close the tumble control valves (w/ TCV).

       Standard
       Tester Connection Specified Condition Positive (+) battery voltage applied to terminal 8 (M-), and negative (-) battery voltage applied to terminal 4 (M+) Open → Closed

       Note

       
       

       • If this procedure is not performed, the tumble control valves may be damaged when the intake manifold is removed.

       • Apply battery voltage for 1 to 3 seconds.

       • If battery voltage is applied for more than 3 seconds, the intake air control valve actuator may be damaged.

       • Do not allow the lead wires to contact the other terminals.

    7. 

       Text in Illustration

       *A	w/ TCV
       *B	w/o TCV

       Remove the bolt and separate the wire harness.

    8. Disengage the 2 wire harness clamps and disconnect the intake air control valve actuator connector (w/ TCV).

    9. Disengage the 2 wire harness clamps (w/o TCV).

    10. 

        Remove the 6 bolts and intake manifold (w/ TCV).

        Note

        The tumble control valves may be damaged if they are not closed before removing the intake manifold.

        Tech Tips

        Connect the battery to the terminals of the intake air control valve actuator to operate the motor and close the tumble control valves Click here.

    11. 

        Remove the 6 bolts and intake manifold (w/o TCV).

    12. 

        Remove the intake manifold gasket from the intake manifold (w/ TCV).

    13. 

        Remove the intake manifold gasket from the intake manifold (w/o TCV).

    14. 

        Disconnect the 2 vacuum hoses from the intake manifold to remove the No. 1 check valve.

    15. 

        Remove the bolt and wire harness clamp bracket from the intake manifold.