FUEL PRESSURE PULSATION DAMPER (for Port Injection) REMOVAL


  1. PRECAUTION

  2. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A0160IP

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the 2 clips on the rear of the cover and remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  3. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A015ZFO

      Remove the 9 clips and cool air intake duct seal.

  4. REMOVE ENGINE ROOM SIDE COVER RH (for LHD)


    1. A0161AL

      Remove the 3 clips and engine room side cover RH.

  5. REMOVE ENGINE ROOM SIDE COVER RH (for RHD)


    1. A015YK3

      Remove the 4 clips and engine room side cover RH.

  6. REMOVE ENGINE ROOM SIDE COVER LH (for LHD)


    1. A016120

      Remove the 5 clips and engine room side cover LH.

  7. REMOVE ENGINE ROOM SIDE COVER LH (for RHD)


    1. A015Z63

      Remove the 4 clips and engine room side cover LH.

  8. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge fuel system pressure Click here.

  9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  10. REMOVE NO. 1 AIR CLEANER INLET


    1. A01612G

      Remove the bolt, clip and No. 1 air cleaner inlet.

  11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A015YRW

      Loosen the 2 hose clamps and separate the 2 ventilation hoses.

    2. A01622I

      Disconnect the mass air flow meter connector and separate the wire harness clamp.

    3. A015ZWF

      Loosen the hose clamp and separate the air cleaner hose.

    4. A015YT4

      Unlock the 2 clamps and remove the air cleaner cap sub-assembly.

  12. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A0163D8

      Remove the 2 clamps and disconnect the vacuum hose.

    2. A015ZYF

      Remove the clamp and disconnect the vacuum switching valve connector.

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

  13. REMOVE ENGINE UNDER COVER

  14. DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug.

      CAUTION:

      Do not loosen the radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

      Tech Tips

      Collect the coolant in a container and dispose of it according to local regulations.

    2. A0161WSE01

      Remove the radiator reservoir cap, and using a 6 mm socket hexagon wrench, remove the vent plug.

    3. Drain coolant.

    4. Loosen the 2 cylinder block drain cock plugs.

      A01603GE01

  15. SEPARATE ENGINE WIRE


    1. A015ZSI

      Disconnect the harness clamp and then separate the engine wire.

  16. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. A015ZPT

      Disconnect the fuel vapor feed hose from the intake air surge tank assembly.

    2. Remove the No. 2 fuel vapor feed hose from the No. 1 vacuum switching valve assembly.

    3. Remove the bolt and No. 1 vacuum switching valve assembly.

    4. Disconnect the ventilation hose.

  17. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A016088E01

      Slide the 5 clamps, and disconnect the heater inlet water hose, heater outlet water hose, water inlet hose, water outlet hose , and water by-pass hose from the water by-pass pipe sub-assembly.

    2. Remove the 2 bolts and water by-pass pipe.

  18. REMOVE NO. 3 FUEL HOSE


    1. A0160LG

      Remove the 2 fuel pipe clamps.

    2. A0162L9E01

      Pinch the fuel tube connector and then pull out the No. 3 fuel hose.

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

  19. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (for Port Injection)


    1. A016290

      Disconnect the 4 connectors.

    2. Remove the 2 bolts and wire harness.

    3. A01630T

      Disconnect the 4 connectors.

    4. Remove the 2 bolts and wire harness.

    5. A0161QCE01

      Using SST, loosen the 2 fuel pressure pulsation dampers.

      SST
      09612-24014   ( 09617-24011 )

    6. Remove the fuel tube sub-assembly with the 4 gaskets.