INTAKE MANIFOLD REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine 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 notices before proceeding with work.

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  2. DISCHARGE FUEL SYSTEM PRESSURE

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  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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

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

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  7. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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  8. REMOVE V-BANK COVER SUB-ASSEMBLY

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  9. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for RHD)

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  10. REMOVE RESERVOIR BRACKET (for RHD)

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  11. DISCONNECT VENTILATION HOSE


    1. A0028BA

      Slide the clip and disconnect the ventilation hose from the intake air surge tank assembly.

  12. DISCONNECT PURGE VALVE (PURGE VSV)


    1. A00271Y

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

    2. Remove the bolt and disconnect the purge valve (purge VSV) from the intake air surge tank assembly.

  13. REMOVE NO. 2 SURGE TANK STAY


    1. A0028A4

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

  14. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. A00296J

      Disconnect the vacuum switching valve (for ACIS) connector.

    2. Disengage the 2 clamps to disconnect the vacuum hose sub-assembly from the intake air surge tank assembly.

    3. A002BLXC01
      *1 Vacuum Hose Sub-assembly
      *2 No. 2 Air Tube

      Disengage the 2 clamps to disconnect the vacuum hose sub-assembly from the intake air surge tank assembly.

    4. Disengage the clamp to disconnect the No. 2 air tube from the intake air surge tank assembly.

    5. A002AX8C01
      B003ZIE Bolt
      B003Z8F Nut

      Remove the 5 bolts, 2 nuts and intake air surge tank assembly from the intake manifold.

  15. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET


    1. A002ADT

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

  16. REMOVE NO. 1 V-BANK COVER BRACKET

    Tech Tips

    Perform this procedure only when replacement of the No. 1 V-bank cover bracket is necessary.


    1. A002BH3

      Remove the 2 No. 1 V-bank cover brackets from the intake air surge tank assembly.

  17. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A0028CDC01
      B003ZIE Bolt
      B003Z8F Nut

      Remove the bolt, 2 nuts and No. 2 engine mounting stay RH from the engine moving control rod.

    2. A002CAL

      Disengage the wire harness clamp from the wire harness clamp bracket.

    3. A002C7M

      Remove the bolt and wire harness clamp bracket from the No. 2 engine mounting stay RH.

    4. A0028D8

      Remove the bolt and No. 2 engine mounting stay RH from the intake manifold and engine mounting insulator sub-assembly RH.

  18. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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  19. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

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  20. REMOVE NO. 1 DELIVERY PIPE SPACER

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  21. REMOVE INJECTOR VIBRATION INSULATOR

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  22. REMOVE INTAKE MANIFOLD


    1. A00291OC01
      B003ZIE Bolt
      B003Z8F Nut

      Remove the 4 bolts, 4 nuts and intake manifold from the cylinder head sub-assembly.

  23. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET


    1. A002B4H

      Remove the 2 No. 1 intake manifold to head gaskets from each cylinder head sub-assembly.

  24. REMOVE STUD BOLT

    Tech Tips

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


    1. A002C52

      Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.