INTAKE MANIFOLD REMOVAL

PROCEDURE


  1. REMOVE INTERCOOLER ASSEMBLY

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  2. REMOVE GENERATOR ASSEMBLY

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  3. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

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  4. REMOVE SUSPENSION TOWER DAMPER (w/ Performance Damper)


    1. A01OE78

      Remove the 2 nuts and suspension tower damper.

  5. REMOVE SUSPENSION TOWER DAMPER (w/o Performance Damper)

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  6. REMOVE OUTER COWL TOP PANEL (for LHD)


    1. Disconnect the connector.

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

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

      A01OES2C02
      B0057RX Connector B0059IK Bolt

  7. REMOVE OUTER COWL TOP PANEL (for RHD)


    1. Disconnect the connector.

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

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

      A01OEXZC03
      B0057RX Connector B0059IK Bolt

  8. REMOVE PURGE VSV

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  9. DISCONNECT WATER BY-PASS HOSE


    1. A01OF5U

      Slide the 2 clips and disconnect the No. 5 sub-radiator hose and No. 6 sub-radiator hose from the No. 2 water by-pass pipe.

  10. DISCONNECT ENGINE WIRE


    1. A01OE6A

      Disconnect the 3 connectors and detach the wire harness clamp.

    2. Remove the bolt and nut from the wire harness bracket.

    3. A01OE0B

      Remove the bolt, detach the wire harness clamp and disconnect the wire harness.

    4. A01OEGN

      Disconnect the 7 connectors and detach the 3 clamps.

    5. A01OENO

      Disconnect the 3 connectors, detach the 2 clamps and disconnect the engine wire.

    6. Remove the ground bolt.

  11. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A01OER8

      Remove the 3 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly and No. 2 vacuum switching valve bracket.

  12. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01ODXS

      Detach the clamp and disconnect the No. 2 vacuum transmitting hose assembly from the vacuum pump assembly and cylinder head cover sub-assembly.

  13. REMOVE NO. 2 TURBO PRESSURE SENSOR

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  14. REMOVE NO. 1 VACUUM TRANSMITTING HOSE


    1. A01OF03

      Detach the clamp and disconnect the No. 1 vacuum transmitting hose from the intake manifold.

  15. DISCONNECT VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01OF6F

      Detach the 5 clamps and disconnect the vacuum transmitting hose assembly from the cylinder head cover sub-assembly.

    2. A01OE14

      Disconnect the vacuum transmitting hose assembly from the waste gate valve actuator with bracket assembly.

  16. REMOVE NO. 2 PCV HOSE


    1. A01OE4G

      Slide the 2 clamps and remove the No. 2 PCV hose from the intake manifold and cylinder head cover sub-assembly.

  17. DISCONNECT THROTTLE BODY WATER BY-PASS HOSE


    1. A01OF4VC01
      *1 No. 1 Water By-pass Hose
      *2 No. 2 Water By-pass Hose

      Slide the clamp and disconnect the No. 2 water by-pass hose from the No. 1 water by-pass pipe.

    2. Slide the clamp and disconnect the No. 1 water by-pass hose from the cylinder head sub-assembly.

  18. REMOVE INTAKE MANIFOLD


    1. A01OF69

      Remove the bolt.

    2. A01OEEV

      Remove the 3 bolts, 2 nuts and intake manifold.

    3. A01OEY5

      Remove the 2 nuts, No. 1 water by-pass hose and No. 2 water by-pass hose.

    4. A01ODXW

      Remove the 2 bolts and intercooler support bracket sub-assembly.

      Note

      Align the intercooler support bracket sub-assembly with its marked original position and removal it.

    5. A01OF8C

      Remove the bolt and bracket wire harness clamp bracket.

    6. A01OE45

      Remove the 2 intake manifold gaskets from the intake manifold.

  19. REMOVE NO. 2 FUEL VAPOR FEED HOSE


    1. A01OE34

      Slide the clamp and remove the No. 2 fuel vapor feed hose from the intake manifold.

  20. REMOVE BRACKET


    1. A01OESW

      Remove the bolt from the intake manifold.

  21. REMOVE NO. 3 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01OEDD

      Detach the 2 clamps.

    2. A01ODZP

      Remove the No. 3 vacuum transmitting hose from the vacuum surge tank.

  22. REMOVE NO. 1 TURBO PRESSURE SENSOR


    1. A01OF7T

      Remove the bolt and No. 1 turbo pressure sensor.

  23. REMOVE VACUUM REGULATING VALVE ASSEMBLY

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  24. REMOVE NO. 4 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01OF7H

      Detach the 2 clamps and remove the No. 4 vacuum transmitting hose assembly from the vacuum surge tank.

  25. REMOVE VACUUM SURGE TANK


    1. A01OE9O

      Remove the 3 bolts and vacuum surge tank.