INTAKE MANIFOLD REMOVAL

PROCEDURE

1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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2. REMOVE FRONT NO. 1 VENTILATOR SEAL (for LHD)

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3. REMOVE FRONT NO. 1 VENTILATOR SEAL (for RHD)

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4. REMOVE FRONT AIR SHUTTER SEAL RH (for LHD)

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5. REMOVE FRONT AIR SHUTTER SEAL RH (for RHD)

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6. REMOVE INNER COWL TOP TO COWL BRACE (for LHD)

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7. REMOVE INNER COWL TOP TO COWL BRACE (for RHD)

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8. REMOVE OUTER COWL TOP PANEL (for LHD)

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9. REMOVE OUTER COWL TOP PANEL (for RHD)

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10. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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11. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR

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12. DISCONNECT VACUUM HOSE ASSEMBLY

    
    

    1. 

       Text in Illustration

       *a	Retainer
       	Pinch
       	Pull

       Pinch the retainer of the vacuum hose assembly connector, and then pull the vacuum hose assembly connector off of the intake manifold.

       Note

       Be sure to disconnect the vacuum hose assembly connector by hand.

    2. Disengage the clamp to disconnect the vacuum hose assembly from the vacuum hose clamp.

    3. for RHD:

       
       

       1. 

          Disengage the clamp to disconnect the vacuum hose assembly from the vacuum hose clamp.

13. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE

    
    

    1. 

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

14. REMOVE INTAKE MANIFOLD

    
    

    1. 

       Disengage the clamp to disconnect the fuel tube sub-assembly from the fuel hose clamp.

    2. 

       Text in Illustration

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

       Disengage the 4 clamps to disconnect the No. 1 water by-pass hose and No. 2 water by-pass hose from the intake manifold.

    3. 

       Disengage the 3 clamps to disconnect the wire harness from the intake manifold and wire harness clamp bracket.

    4. 

       Text in Illustration

       *1	Wire Harness Clamp Bracket
       *2	Fuel Hose Bracket

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

    5. Remove the bolt and fuel hose bracket from the intake manifold.

    6. 

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

15. REMOVE VACUUM HOSE CLAMP

    
    

    1. for LHD:

       
       

       1. 

          Disengage the clamp to remove the vacuum hose clamp from the intake manifold.

    2. for RHD:

       
       

       1. 

          Disengage the 2 clamps to remove the 2 vacuum hose clamps from the intake manifold.

16. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

    
    

    1. 

       Remove the No. 1 intake manifold to head gasket from the intake manifold.

17. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    
    

    1. 

       Remove the 2 bolts, nut and No. 1 intake manifold insulator from the EGR valve assembly.

18. REMOVE NO. 2 INTAKE MANIFOLD TO HEAD GASKET

    
    

    1. 

       Remove the No. 2 intake manifold to head gasket from the cylinder head sub-assembly.

19. REMOVE EGR VALVE ASSEMBLY

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20. REMOVE EGR VALVE GASKET

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