INTAKE MANIFOLD REMOVAL

PROCEDURE

1. Click here

   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. Click here

   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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3. Click here

   REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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4. Click here

   REMOVE PURGE VALVE (PURGE VSV)

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5. Click here

   REMOVE FRONT SUSPENSION UPPER TO COWL BRACE LH

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6. Click here

   REMOVE FRONT SUSPENSION UPPER TO COWL BRACE RH

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7. Click here

   REMOVE FRONT SUSPENSION UPPER BRACE BRACKET

   
   

   1. for LHD:

      
      
      1. 

         Disconnect the union to check valve hose from the front suspension upper brace bracket.

   2. for RHD:

      
      
      1. 

         Disconnect the No. 2 engine wire from the front suspension upper brace bracket.

   3. 

      Remove the 2 nuts and front suspension upper brace bracket from the vehicle body.

8. Click here

   REMOVE INJECTOR DRIVER

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9. Click here

   DISCONNECT UNION TO CHECK VALVE HOSE

   
   
   1. 

      *A	for LHD
      *B	for RHD

      Slide the clip and disconnect the union to check valve hose from the intake air surge tank assembly.

10. Click here

    REMOVE ENGINE ROOM ECU COVER

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11. Click here

    REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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12. Click here

    DISENGAGE ENGINE WIRE

    
    

    1. for LHD:

       
       
       1. 

          	Bolt		Nut
          	Connector		Fuel Tube Sub-assembly

          Remove the 2 bolts and 4 nuts.

       2. Disengage the 4 clamps.

       3. Disconnect the 12 connectors.

       4. Disengage the fuel tube sub-assembly from the engine wire.

    2. for RHD:

       
       
       1. 

          	Bolt		Nut
          	Connector		Fuel Tube Sub-assembly

          Remove the 2 bolts and 4 nuts.

       2. Disengage the 5 clamps.

       3. Disconnect the 12 connectors.

       4. Disengage the fuel tube sub-assembly from the engine wire.

    3. 

       	Bolt
       	Connector

       Remove the 2 bolts.

    4. Disengage the 2 clamps.

    5. Disconnect the 4 connectors.

    6. 

       	Bolt
       	Connector

       Remove the 2 bolts.

    7. Disengage the 7 clamps.

    8. Disconnect the 7 connectors.

    9. 

       Disengage the claw and disconnect the engine wire harness.

    10. Disconnect the engine wire harness connector.

    11. Disengage the wire harness from the engine room ECU box.

        Click here

13. Click here

    DISCONNECT NO. 5 ENGINE WIRE

    
    
    1. 

       Disengage the 4 clamps and disconnect the No. 5 engine wire from the intake air surge tank assembly.

14. Click here

    DISCONNECT VACUUM HOSE SUB-ASSEMBLY

    
    
    1. 

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

15. Click here

    REMOVE FUEL VAPOR FEED HOSE

    
    
    1. 

       Slide the clip and remove the fuel vapor feed hose from the intake air surge tank assembly.

16. Click here

    DISCONNECT VENTILATION HOSE

    
    
    1. 

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

17. Click here

    REMOVE INJECTOR DRIVER BRACKET

    
    
    1. 

       Remove the 4 bolts and 2 injector driver brackets from the intake air surge tank assembly, cylinder head cover sub-assembly LH and cylinder head cover sub-assembly.

18. Click here

    REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

    
    
    1. 

       *1	Heater Water Inlet Hose
       *2	Heater Water Outlet Hose

       Remove the 2 water hose sets from the heater water inlet hose and heater water outlet hose.

    2. 

       *1	Heater Water Inlet Hose
       *2	Heater Water Outlet Hose
       *3	No. 3 Water By-pass Hose
       *4	Water By-pass Hose
       *5	No. 5 Water By-pass Hose

       Slide the clip and disconnect the No. 3 water by-pass hose from the water by-pass pipe sub-assembly.

    3. Slide the clip and disconnect the water by-pass hose from the water by-pass pipe sub-assembly.

    4. Slide the clip and disconnect the No. 5 water by-pass hose from the water by-pass pipe sub-assembly.

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

    6. Slide the clip and disconnect the heater water inlet hose from the water by-pass pipe sub-assembly.

    7. 

       Remove the 2 bolts and water by-pass pipe sub-assembly from the intake air surge tank assembly.

19. Click here

    REMOVE FUEL TUBE SUB-ASSEMBLY

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20. Click here

    REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

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21. Click here

    REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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22. Click here

    REMOVE NO. 1 DELIVERY PIPE SPACER

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23. Click here

    REMOVE INJECTOR VIBRATION INSULATOR

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24. Click here

    REMOVE FUEL INJECTOR ASSEMBLY

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25. Click here

    REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY

    
    
    1. 

       Remove the bolt and V-bank cover bracket sub-assembly from the intake air surge tank assembly.

26. Click here

    REMOVE NO. 2 V-BANK COVER BRACKET SUB-ASSEMBLY

    
    
    1. 

       Remove the bolt and No. 2 V-bank cover bracket sub-assembly from the intake air surge tank assembly.

27. Click here

    DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

    
    
    1. 

       Remove the bolt and disconnect the No. 1 fuel pipe sub-assembly from the intake air surge tank assembly.

28. Click here

    REMOVE INTAKE AIR SURGE TANK ASSEMBLY

    
    
    1. 

       *A	for LHD
       *B	for RHD

       Remove the bolt and disconnect the wire harness bracket from the intake air surge tank assembly.

    2. 

       	Bolt
       	Nut

       Remove the 8 bolts and 2 nuts.

    3. 

       Pull the engine wire as shown in the illustration.

    4. 

       Remove the intake air surge tank assembly from the cylinder block sub-assembly.

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