INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during intake manifold removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effects/Inoperative when Necessary Procedure not Performed Link

  • Replacement of throttle body with motor assembly

  • Cleaning the deposits from the throttle body with motor assembly

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

Click here

PROCEDURE


  1. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  2. REMOVE INTERCOOLER ASSEMBLY

    Click here

  3. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

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

    Click here

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

    Click here

  6. REMOVE PURGE VALVE (PURGE VSV)

    Click here

  7. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  8. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

  9. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01VXWEC01
      *a Air Cleaner Support

      Remove the 2 bolts and air cleaner case sub-assembly.

      Note

      Make sure the air cleaner support remains attached to the vehicle body.

  10. DISCONNECT NO. 5 INTERCOOLER COOLING WATER HOSE


    1. A01VUE6

      Slide the clip and disconnect the No. 5 intercooler cooling water hose from the No. 3 Intercooler cooling water pipe.

  11. DISCONNECT NO. 6 INTERCOOLER COOLING WATER HOSE


    1. A01VV9E

      Slide the clip and disconnect the No. 6 intercooler cooling water hose from the No. 2 Intercooler cooling water pipe.

  12. DISCONNECT ENGINE WIRE


    1. A01VUMGC02
      B005NIZ Bolt
      B005LWS Connector

      Disconnect the 3 sensor wire connectors.

    2. Disengage the wire harness clamp from the wire harness bracket.

    3. Remove the 2 bolts from the wire harness bracket.

    4. A01VXD9

      Remove the bolt and disconnect the sensor wire from the intercooler support bracket sub-assembly.

    5. Disengage the clamp and remove the sensor wire from the intercooler support bracket sub-assembly.

    6. A01VVXDC01
      B005NIZ Bolt
      B005LWS Connector

      Disconnect the 7 connectors.

    7. Disengage the 4 wire harness clamps.

    8. Remove the bolt.

    9. A01VWLNC01
      B005NIZ Bolt
      B005LWS Connector
      A01VXXI Ground Bolt

      Disconnect the 5 connectors.

    10. Disengage the 4 wire harness clamps.

    11. Remove the ground bolt.

    12. Remove the bolt.

  13. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A01VTKU

      Remove the 3 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly and bracket.

  14. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01VXYC

      Disconnect the No. 2 vacuum transmitting hose assembly from the vacuum pump assembly and cylinder head cover sub-assembly.

  15. REMOVE NO. 1 TURBO PRESSURE SENSOR

    Click here

  16. DISCONNECT VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01VUHF

      Disconnect the vacuum transmitting hose assembly from the vacuum regulating valve assembly.

  17. REMOVE NO. 2 VENTILATION HOSE


    1. A01VU36

      Slide the 2 clips and remove the No. 2 ventilation hose from the intake manifold and PCV valve (ventilation valve sub-assembly).

  18. DISCONNECT WATER BY-PASS HOSE


    1. A01VVUKC01
      *1 No. 1 Water By-pass Hose
      *2 No. 2 Water By-pass Hose

      Slide the clip and disconnect the No. 2 water by-pass hose from the No. 1 water by-pass pipe.

    2. Slide the clip and disconnect the No. 1 water by-pass hose from the cylinder head sub-assembly.

  19. REMOVE INTAKE MANIFOLD


    1. A01VTR1

      Remove the bolt and disconnect the intercooler support bracket sub-assembly from the cylinder block sub-assembly.

    2. A01VUFRC01
      B005NIZ Bolt
      B005LWS Nut

      Remove the 3 bolts, 2 nuts and intake manifold from the cylinder head sub-assembly.

    3. A01VWO4

      Remove the 2 nuts and the manifold thermostat from the intercooler support bracket sub-assembly.

    4. A01VXDR

      Remove the 2 bolts and intercooler support bracket sub-assembly from the intake manifold.

      Note

      Put matchmarks on the intercooler support bracket sub-assembly so that it can be installed to its original position.

    5. A01VWDA

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

    6. A01VXQF

      Remove the 2 No. 1 intake manifold to head gaskets from the intake manifold.

  20. REMOVE NO. 2 FUEL VAPOR FEED HOSE


    1. A01VXXK

      Slide the clip and remove the No. 2 fuel vapor feed hose from the intake manifold.

  21. REMOVE BRACKET


    1. A01VWDF

      Remove the bolt and bracket from the intake manifold.

  22. REMOVE NO. 3 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01VY7G

      Disengage the No. 3 vacuum transmitting hose assembly from the intake manifold.

    2. A01VU5F

      Remove the No. 3 vacuum transmitting hose assembly from the vacuum surge tank and vacuum regulating valve assembly.

  23. REMOVE VACUUM REGULATING VALVE ASSEMBLY


    1. A01VU1Y

      Disconnect the vacuum regulating valve assembly connector.

    2. Remove the 2 bolts and vacuum regulating valve assembly from the intake manifold.

  24. REMOVE NO. 4 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01VY3G

      Remove the No. 4 vacuum transmitting hose assembly from the intake manifold and vacuum surge tank.

  25. REMOVE VACUUM SURGE TANK


    1. A01VVVY

      Remove the 3 bolts and vacuum surge tank from the intake manifold.