INTAKE MANIFOLD REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. PRECAUTION

    Note

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

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  3. REMOVE NO. 3 DECK BOARD SUB-ASSEMBLY

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  4. REMOVE REAR DECK FLOOR BOX (w/ Spare Tire)

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  5. REMOVE DECK FLOOR BOX LH (w/ Spare Tire)

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  6. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

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  7. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

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  8. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

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  9. REMOVE SUSPENSION TOWER DAMPER (w/ Performance Rod)


    1. A01H62G

      Remove the 2 nuts and suspension tower damper.

  10. REMOVE OUTER COWL TOP PANEL (for LHD)


    1. w/o Performance Rod:


      1. Disconnect the connector.

      2. Detach the 4 clamps and disconnect the wire harness.

      3. Remove the 13 bolts, 2 nuts and outer cowl top panel.

        B002JZRC01
        B002HVY Connector B002I10 Bolt
        B002H26 Nut - -

    2. w/ Performance Rod:


      1. Disconnect the connector.

      2. Detach the 4 clamps and disconnect the wire harness.

      3. Remove the 13 bolts and outer cowl top panel.

        B002KCTC01
        B002HVY Connector B002I10 Bolt

  11. REMOVE OUTER COWL TOP PANEL (for RHD)


    1. w/o Performance Rod:


      1. Disconnect the connector.

      2. Detach the 4 clamps and disconnect the wire harness.

      3. Remove the 13 bolts, 2 nuts and outer cowl top panel.

        B002HW1C03
        B002HVY Connector B002I10 Bolt
        B002H26 Nut - -

    2. w/ Performance Rod:


      1. Disconnect the connector.

      2. Detach the 4 clamps and disconnect the wire harness.

      3. Remove the 13 bolts and outer cowl top panel.

        B002HJFC03
        B002HVY Connector B002I10 Bolt

  12. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  14. REMOVE EGR VALVE ASSEMBLY (w/ EGR System)

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  15. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR

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  16. DISCONNECT ENGINE WIRE


    1. B002KPC

      Disconnect the heated oxygen sensor connector.

    2. B002IFR

      Detach the 6 clamps and disconnect the engine wire.

  17. DISCONNECT INTAKE MANIFOLD


    1. B002KUB

      Slide the clamp and disconnect the No. 2 PCV hose from the intake manifold.

    2. B002IMC

      Remove the 6 bolts and disconnect the intake manifold.

  18. DISCONNECT NO. 1 EGR PIPE (w/ EGR System)


    1. B002KMC

      Remove the nut and bolt, and then disconnect the No. 1 EGR pipe from the EGR cooler assembly.

    2. Remove the 2 bolts and disconnect the No. 1 EGR pipe.

    3. Remove the gasket from the No. 1 EGR pipe.

  19. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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  20. REMOVE FUEL DELIVERY PIPE

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  21. REMOVE INTAKE MANIFOLD


    1. Remove the intake manifold from the vehicle.

    2. B002KUS

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

    3. B002H3A

      Remove the bolt and wiring harness clamp bracket.

    4. B002KY2

      Remove the vacuum hose from the intake manifold.

    5. B002KIQ

      Slide the clamp and disconnect the purge line hose from the intake manifold.

  22. REMOVE INTAKE FLANGE (w/o EGR System)


    1. B002KBS

      Remove the engine cover joint from the intake flange.

    2. Remove the 3 bolts and intake flange.

    3. Remove the gasket from the intake manifold.