INTAKE MANIFOLD REMOVAL


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

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


    1. B000L2Z

      Disengage the 2 clamps and separate the wire harness from the front outer cowl top panel sub-assembly.

    2. B000GWP

      Remove the 10 bolts and front outer cowl top panel sub-assembly.

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


    1. w/ Windshield Deicer System:


      1. B000HLG

        Disengage the 2 clamps.

      2. Disconnect the connector and separate the wire harness from the front outer cowl top panel sub-assembly.

    2. w/ Heated Windshield Defroster System:


      1. B000HSG

        Disengage the 4 clamps.

      2. Disconnect the 2 connectors and separate the wire harness from the front outer cowl top panel sub-assembly.

    3. B000KY4

      Disengage the 2 clamps and separate the wire harness from the front outer cowl top panel sub-assembly.

    4. B000KRD

      Remove the 10 bolts and front outer cowl top panel sub-assembly.

  7. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  8. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. B000K2T

      Disconnect the union to connector tube hose and wire harness clamp.

    2. Disconnect the 2 vacuum hoses and connector.

    3. Remove the bolt and vacuum switching valve assembly.

  9. DISCONNECT NO. 2 VENTILATION HOSE


    1. B000MDG

      Disconnect the No. 2 ventilation hose from the intake manifold.

  10. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. B000GXB

      Disconnect the union to connector tube hose from the intake manifold.

  11. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Note

    Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


    1. B000LXNE01

      Disengage the claw and remove the No. 1 fuel pipe clamp.

    2. Disconnect the fuel tube sub-assembly from the fuel pipe.


      1. B000HU0E03
        Text in Illustration
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe
        *e Nylon Tube
        B000K70 Pinch
        B000IB9 Pull

        Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

        • Do not forcibly bend, twist or turn the nylon tube.

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

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

  12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B000JXH

      Remove the 2 bolts and fuel delivery pipe sub-assembly with the 4 fuel injector assemblies.

      Note

      Do not drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

    2. B000N6RE01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *2 Injector Vibration Insulator

      Remove the 2 fuel delivery spacers from the cylinder head.

    3. Remove the 4 injector vibration insulators from the cylinder head.

  13. REMOVE INTAKE MANIFOLD


    1. B000M0E

      Remove the 2 bolts and 2 wire harness clamp brackets.

    2. B000MD8

      Disconnect the fuel vapor feed hose.

    3. Disconnect the 3 wire harness clamps and connector.

    4. Remove the bolt and wire harness clamp bracket.

    5. B000H4G

      Apply battery voltage to the terminals of the connector to close the tumble control valves (w/ TCV).

      Standard
      Tester Connection Specified Condition
      Positive (+) battery voltage applied to terminal 8 (M-), and negative (-) battery voltage applied to terminal 4 (M+) Open → Closed

      Note


      • If this procedure is not performed, the tumble control valves may be damaged when the intake manifold is removed.

      • Apply battery voltage for 1 to 3 seconds.

      • If battery voltage is applied for more than 3 seconds, the actuator may be damaged.

      • Do not allow the lead wires to contact the other terminals.

    6. B000MXZE01

      Remove the bolt and separate the wire harness.

    7. Disconnect the 2 wire harness clamps and intake air control valve actuator connector (w/ TCV).

    8. Disconnect the 2 wire harness clamps (w/o TCV).

      Text in Illustration
      *A w/ TCV
      *B w/o TCV
    9. B000K5V

      Remove the 6 bolts and intake manifold (w/ TCV).

      Note

      The tumble control valves may be damaged if they are not closed before removing the intake manifold.

      Tech Tips

      Connect the battery to the terminals of the actuator to operate the motor and close the valves Click here.

    10. B000M9A

      Remove the 6 bolts and intake manifold (w/o TCV).

    11. B000LUC

      Remove the intake manifold gasket from the intake manifold (w/ TCV).

    12. B000K60

      Remove the intake manifold gasket from the intake manifold (w/o TCV).

    13. B000J2C

      Disconnect the 2 vacuum hoses from the intake manifold and remove the No. 1 check valve.

    14. B000IDI

      Remove the bolt and wire harness clamp bracket.