INTAKE MANIFOLD REMOVAL


  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 notice before proceeding with work Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly, cylinder block drain cock plugs or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

    2. Loosen the cylinder block drain cock plug. (for Bank 1)

    3. Loosen the cylinder block drain cock plug. (for Bank 2, w/ Cylinder Block Drain Cock Plug)

    4. Remove the radiator cap sub-assembly.

      A01G49BE04
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Cylinder Block Drain Cock Plug (for Bank 1)
      *3 Cylinder Block Drain Cock Plug (for Bank 2, w/ Cylinder Block Drain Cock Plug) *4 Radiator Drain Cock Plug
      *5 Air Drain Cock Plug - -

      Tech Tips

      Collect the engine coolant in a container and dispose of it according to the regulations in your area.

  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

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


    1. A01G885E01

      w/ Wiper Deicer System:

      Disengage the clamp (A).

    2. Disengage the 2 clamps (B).

    3. Disconnect the connector and separate the wire harness from the front outer cowl top panel sub-assembly.

    4. A01G5UB

      Disengage the 2 clamps and separate the wire harness from the front outer cowl top panel sub-assembly.

    5. A01G71P

      Remove the 10 bolts and front outer cowl top panel sub-assembly.

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


    1. A01G4NT

      Disengage the 2 clamps and separate the wire harness from the front outer cowl top panel sub-assembly.

    2. A01G6BQ

      Remove the 10 bolts and front outer cowl top panel sub-assembly.

  8. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01G4T2

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the retainer on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01G55V

      Disconnect the mass air flow meter connector and wire harness clamp.

    2. A01G6Q3

      Disconnect the 3 hoses.

    3. Disconnect the ventilation hose from the air cleaner cap sub-assembly.

    4. A01G67K

      Loosen the hose clamp and separate the air cleaner cap sub-assembly from the throttle with motor body assembly.

    5. Release the 2 clamps and remove the air cleaner cap sub-assembly.

  10. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. A01G6NLE01
      Text in Illustration
      *A Type A
      *B Type B

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

    2. for LHD:


      1. A01G7SWE01
        Text in Illustration
        *A for LHD
        *B for RHD

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

      2. Disengage the hose clamp.

    3. for RHD:


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

    4. A01G66K

      Disconnect the throttle body assembly connector.

    5. Disengage the wire harness clamp.

    6. Slide the 2 clips and disconnect the 2 water by-pass hoses from the throttle body assembly.

    7. Disconnect the fuel vapor feed hose from the intake air surge tank assembly.

    8. A01G4H7

      Disconnect the intake air control valve assembly connector.

    9. A01G4FU

      Remove the bolt and vacuum hose clamp from the throttle body bracket.

    10. A01G7HH

      Remove the bolt and separate the throttle body bracket from the intake air surge tank assembly.

    11. A01G5H8

      Remove the bolt and separate the No. 1 surge tank stay from the intake air surge tank assembly.

    12. A01G57K

      Remove the 2 nuts from the intake air surge tank assembly.

    13. Using a 5 mm hexagon socket wrench, remove the 4 bolts from the intake air surge tank assembly.

    14. A01G8QN

      Remove the intake air surge tank assembly and 3 gaskets.

  11. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting stay Side)


    1. A01G6F6

      Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

  12. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side)


    1. A01G76Q

      Remove the bolt and No. 2 engine mounting stay RH.

  13. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01G8I8E09
      Text in Illustration
      *1 No. 2 Fuel Pipe Clamp
      *2 Fuel Tube Connector
      *3 Nylon Tube
      *4 O-ring
      *5 Fuel Pipe
      A01G8AH Pinch
      A01G47H Pull

      Remove the No. 2 fuel pipe clamp.

    2. Pinch the fuel tube connector and pull out the fuel pipe.

      Note


      • Check for foreign matter on the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe.

      • Do not use any tools to separate the fuel tube connector and fuel pipe.

      • Do not forcibly bend, kink or twist the nylon tube.

      • Keep the connector and fuel pipe free from foreign matter.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

      • Cover the fuel tube connector and fuel pipe with plastic bags to prevent damage and contamination.

  14. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01G5A7

      Disconnect the 6 fuel injector connectors.

    2. A01G5Q8

      Remove the 5 bolts and fuel delivery pipe sub-assembly together with the 6 fuel injector assemblies.

      Note

      Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

    3. A01G5P3E01

      Remove the 6 injector vibration insulators from the intake manifold.

  15. REMOVE INTAKE MANIFOLD


    1. A01G4HJ

      Remove the 6 bolts, 4 nuts and intake manifold from the cylinder head sub-assembly.

    2. A01G9ME

      Remove the 2 gaskets from each cylinder head sub-assembly.