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. 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. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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  4. REMOVE PURGE VALVE (PURGE VSV)

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  5. REMOVE FRONT SUSPENSION UPPER TO COWL BRACE LH

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  6. REMOVE FRONT SUSPENSION UPPER TO COWL BRACE RH

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  7. REMOVE FRONT SUSPENSION UPPER BRACE BRACKET


    1. for LHD:


      1. B0066HW

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

    2. for RHD:


      1. B0067PI

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

    3. B0066ON

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

  8. REMOVE INJECTOR DRIVER

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  9. DISCONNECT UNION TO CHECK VALVE HOSE


    1. B0067FVC01
      *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. REMOVE ENGINE ROOM ECU COVER

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  11. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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  12. DISENGAGE ENGINE WIRE


    1. for LHD without differential pressure sensor:


      1. Remove the 2 bolts and 4 nuts.

        B0065XEC01
        B0067U9 Bolt B00679M Nut
        B00683Y Connector B0067MG Fuel Tube Sub-assembly

      2. Disengage the 4 clamps.

      3. Disconnect the 12 connectors.

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

    2. for LHD with differential pressure sensor:


      1. Remove the 2 bolts and 4 nuts.

        B0065GAC01
        B0067U9 Bolt B00679M Nut
        B00683Y Connector B0067MG Fuel Tube Sub-assembly

      2. Disengage the 4 clamps.

      3. Disconnect the 14 connectors.

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

    3. for RHD without differential pressure sensor:


      1. Remove the 2 bolts and 4 nuts.

        B0065ROC01
        B0067U9 Bolt B00679M Nut
        B00683Y Connector B0067MG Fuel Tube Sub-assembly

      2. Disengage the 5 clamps.

      3. Disconnect the 12 connectors.

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

    4. for RHD with differential pressure sensor:


      1. Remove the 2 bolts and 4 nuts.

        B0067WSC01
        B0067U9 Bolt B00679M Nut
        B00683Y Connector B0067MG Fuel Tube Sub-assembly

      2. Disengage the 5 clamps.

      3. Disconnect the 14 connectors.

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

    5. B006600C03
      B0067U9 Bolt
      B00679M Connector

      Remove the 2 bolts.

    6. Disengage the 2 clamps.

    7. Disconnect the 4 connectors.

    8. B0066CIC01
      B0067U9 Bolt
      B00679M Connector

      Remove the 2 bolts.

    9. Disengage the 7 clamps.

    10. Disconnect the 7 connectors.

    11. B0065LL

      Disengage the claw and disconnect the engine wire harness.

    12. Disconnect the engine wire harness connector.

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

      Click here

  13. DISCONNECT NO. 5 ENGINE WIRE


    1. B0067E2

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

  14. DISCONNECT VACUUM HOSE SUB-ASSEMBLY


    1. B0065RJ

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

  15. REMOVE FUEL VAPOR FEED HOSE


    1. B0065IE

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

  16. DISCONNECT VENTILATION HOSE


    1. B0066VF

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

  17. REMOVE INJECTOR DRIVER BRACKET


    1. B00686F

      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. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B0065ISC01
      *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. B006539C01
      *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. B006534

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

  19. REMOVE FUEL TUBE SUB-ASSEMBLY

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  20. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

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  21. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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  22. REMOVE NO. 1 DELIVERY PIPE SPACER

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  23. REMOVE INJECTOR VIBRATION INSULATOR

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  24. REMOVE FUEL INJECTOR ASSEMBLY

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  25. REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY


    1. B00652I

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

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


    1. B006644

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

  27. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B00658P

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

  28. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. B0066ACC01
      *A for LHD
      *B for RHD

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

    2. B00670WC01
      B0067U9 Bolt
      B00679M Nut

      Remove the 8 bolts and 2 nuts.

    3. B0066R5

      Pull the engine wire as shown in the illustration.

    4. B0067HJ

      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.