INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

CAUTION:


  • B004A7G

    Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

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  • B004BJX

    To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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  3. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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  4. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. B000QUZ

      Disconnect the purge VSV connector.

    2. Disconnect the No. 1 fuel vapor feed hose from the intake air surge tank assembly.

    3. Remove the bolt to disconnect the purge VSV from the intake air surge tank assembly.

    4. B000QL3

      Disconnect the vacuum sensor connector.

    5. Detach the 3 clamps.

    6. Remove the bolt to disconnect the wire harness.

    7. Detach the clamp to disconnect the No. 1 fuel tube sub-assembly.

    8. B000SBP

      for RHD:

      Detach the 2 clamps to disconnect the motor cable and generator cable.

    9. B000OA0

      Detach the 2 clamps to disconnect the transmission breather assembly.

    10. B000QF3

      Slide the clamp and disconnect the PCV hose from the intake air surge tank assembly.

    11. B000OH6

      Remove the 2 bolts and No. 2 surge tank stay from the intake air surge tank assembly and camshaft housing sub-assembly LH.

    12. B000PWUC01
      B004C4F Bolt
      B004ANI Nut

      Remove the 2 nuts.

    13. Remove the 5 bolts and intake air surge tank assembly.

    14. Remove the air surge tank to intake manifold gasket from the intake air surge tank assembly.

  5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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  6. REMOVE FUEL TUBE SUB-ASSEMBLY

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  7. DISCONNECT WIRE HARNESS

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  8. DISCONNECT FUEL DELIVERY PIPE SUB-ASSEMBLY

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  9. DISCONNECT GENERATOR CABLE AND MOTOR CABLE (for LHD)

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  10. DISCONNECT NO. 15 WATER BY-PASS HOSE

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  11. REMOVE WATER BY-PASS HOSE

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  12. REMOVE EGR VALVE ASSEMBLY

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  13. REMOVE INTAKE MANIFOLD


    1. B000Q8ZC01
      B004C4F Bolt
      B004ANI Nut

      Remove the 4 bolts, 4 nuts and intake manifold.

    2. B000NUH

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

  14. REMOVE STUD BOLT

    Tech Tips

    If a stud bolt is deformed or the threads are damaged, replace it.


    1. B000RED

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.