INTAKE MANIFOLD REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    Note

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

  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 LH (for LHD)


    1. A016120

      Remove the 5 clips and engine room side cover LH.

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


    1. A015Z63

      Remove the 4 clips and engine room side cover LH.

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


    1. A0161AL

      Remove the 3 clips and engine room side cover RH.

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


    1. A015YK3

      Remove the 4 clips and engine room side cover RH.

  8. REMOVE NO. 1 AIR CLEANER INLET


    1. A01612G

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

  9. 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.

  10. 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.

  11. REMOVE NO. 1 ENGINE ROOM RELAY BLOCK COVER (for LHD)


    1. Remove the No. 1 engine room relay block cover.

  12. REMOVE ENGINE UNDER COVER

  13. REMOVE REAR ENGINE UNDER COVER RH

  14. REMOVE NO. 2 ENGINE UNDER COVER

  15. 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

  16. REMOVE THROTTLE BODY ASSEMBLY


    1. A0162PC

      Disconnect the throttle body assembly connector.

    2. A0162ZZ

      Loosen the hose clamp and separate the No. 5 water by-pass hose.

    3. A0162X5

      Loosen the hose clamp and separate the No. 4 water by-pass hose.

    4. A01628P

      Remove the 2 bolts and 2 nuts.

    5. A01631Y

      Using a "TORX" socket E6, remove the 2 stud bolts and throttle body assembly.

      Note

      Do not damage the water hoses when removing the throttle body assembly.

    6. Remove the gasket.

    7. A0161EH

      Remove the 2 water by-pass hoses from the throttle body assembly.

  17. SEPARATE OIL COOLER TUBE SUB-ASSEMBLY


    1. A0161P0

      Remove the 2 bolts and separate the oil cooler tube sub-assembly.

  18. DISCONNECT ENGINE WIRE (for LHD)

    Tech Tips

    Secure disconnected harnesses, etc. with tape or equivalent so that they do not interfere.


    1. Disconnect the engine wire.


      1. Remove the 2 bolts from the No. 3 exhaust manifold heat insulator. (A)

        A0160O7E01

      2. Disconnect the starter connector. (B)

      3. Disconnect the 2 connectors and then remove the nut. (C)

      4. Disconnect the generator connector and 2 clamps. (D)

      5. Remove the bolt, nut and separate the oil cooler tube sub-assembly. (E)

      6. Remove the nut and disconnect the harness from the +B terminal. (F)

      7. Disconnect the 9 connectors and 3 clamps. (G)

      8. Remove the nut and disconnect the wire harness from the relay box. (H)

        A015YYXE01

      9. Disconnect the 4 injector driver connectors. (I)

        Tech Tips

        To disconnect the injector driver connectors, push the claw downward and move the lock lever to release the lock.

      10. Remove the bolt and ground cable. (J)

      11. Disconnect the 4 connectors and 5 clamps. (K)

      12. Remove the 4 nuts and disconnect the engine wire. (L)

  19. DISCONNECT ENGINE WIRE (for RHD)

    Tech Tips

    Secure disconnected harnesses, etc. with tape or equivalent so that they do not interfere.


    1. Disconnect the engine wire.


      1. Remove the 2 bolts from the No. 3 exhaust manifold heat insulator. (A)

        A0160O7E01

      2. Disconnect the starter connector. (B)

      3. Disconnect the 2 connectors and then remove the nut. (C)

      4. Disconnect the generator connector and 2 clamps. (D)

      5. Remove the bolt, nut and separate the oil cooler tube sub-assembly. (E)

      6. Remove the nut and disconnect the harness from the +B terminal. (F)

      7. Disconnect the 9 connectors and 3 clamps. (G)

      8. Disconnect the 4 injector driver connectors. (H)

        A01630VE01

        Tech Tips

        To disconnect the injector driver connectors, push the claw downward and move the lock lever to release the lock.

      9. Remove the bolt and ground cable. (I)

      10. Disconnect the 4 connectors and 3 clamps. (J)

      11. Remove the 4 nuts and disconnect the engine wire. (K)

  20. 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.

  21. REMOVE INJECTOR DRIVER


    1. A01606BE01

      Disconnect the 4 injector driver connectors.

      Tech Tips

      To disconnect the injector driver connectors, push the claw downward and move the lock lever to release the lock.

    2. Remove the 8 nuts and 2 injector drivers.

    3. Remove the bolt and No. 2 V-bank cover bracket sub-assembly.

  22. 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.

  23. DISCONNECT VACUUM HOSE ASSEMBLY (for LHD)


    1. A0160UP

      Disconnect the vacuum hose assembly from the hose clamp.

    2. Disconnect the vacuum hose assembly from the intake air surge tank assembly.

  24. DISCONNECT VACUUM HOSE ASSEMBLY (for RHD)


    1. A016053

      Disconnect the vacuum hose assembly from the intake air surge tank assembly.

  25. DISCONNECT 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.

  26. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. Disconnect the 8 injector connectors.

    2. Remove the 4 bolts and 2 wire harnesses.

    3. A01610T

      Remove the 4 bolts and fuel delivery pipe sub-assembly and 4 spacers.

  27. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. A0162R3

      Remove the 8 bolts, 2 nuts and intake air surge tank assembly.

    2. Remove the 2 gaskets from the intake air surge tank assembly.

    3. A0162BF

      Remove the bolt and V-bank cover bracket sub-assembly.

    4. Remove the bolt and union to check valve hose bracket (for LHD).