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. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  5. 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.

  6. 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.

  7. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  8. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. for LHD:


      1. A01G9RQ

        Disconnect the union to vacuum tube hose.

      2. Disengage the wire harness clamp.

    2. for RHD:


      1. Disconnect the union to check valve hose.

      2. Disengage the wire harness clamp.

    3. Disconnect the 2 vacuum hoses and vacuum switching valve assembly connector.

    4. Remove the bolt and vacuum switching valve assembly from the intake manifold.

  9. DISCONNECT NO. 2 VENTILATION HOSE


    1. A01G6SM

      Slide the clip and disconnect the No. 2 ventilation hose from the intake manifold.

  10. DISCONNECT UNION TO VACUUM TUBE HOSE (for LHD)


    1. A01G97A

      Slide the clip and disconnect the union to vacuum tube hose from the intake manifold.

  11. DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. A01G97A

      Slide the clip and disconnect the union to check valve hose from the intake manifold.

  12. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Note

    Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


    1. A01G6HQE01

      Disengage the claw and remove the No. 1 fuel pipe clamp.

    2. Disconnect the fuel tube sub-assembly from the fuel pipe.


      1. A01G50PE03
        Text in Illustration
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe
        *e Nylon Tube
        A01G8AH Pinch
        A01G47H Pull

        Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

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

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

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

    3. Disengage the clamp to disconnect the fuel tube sub-assembly from the fuel hose clamp.

  13. REMOVE FUEL DELIVERY PIPE


    1. A01G8C7

      Remove the 2 bolts and fuel delivery pipe with the 4 fuel injector assemblies.

      Note

      Do not drop the fuel injector assemblies when removing the fuel delivery pipe.

    2. A01G960E01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *2 Injector Vibration Insulator

      Remove the 2 fuel delivery spacers from the cylinder head.

    3. Remove the 4 injector vibration insulators from the cylinder head.

  14. REMOVE INTAKE MANIFOLD


    1. A01G73S

      Remove the 2 bolts and 2 wire harness clamp brackets from the intake manifold.

    2. A01G4TD

      Slide the clip and disconnect the fuel vapor feed hose from the intake manifold.

    3. Disengage the 3 wire harness clamps.

    4. Disconnect the wire harness connector.

    5. Remove the bolt and wire harness clamp bracket.

    6. A01G5MYE01

      Apply battery voltage to the terminals of the connector to close the tumble control valves (w/ TCV).

      Standard
      Tester Connection Specified Condition
      Positive (+) battery voltage applied to terminal 8 (M-), and negative (-) battery voltage applied to terminal 4 (M+) Open → Closed

      Note


      • If this procedure is not performed, the tumble control valves may be damaged when the intake manifold is removed.

      • Apply battery voltage for 1 to 3 seconds.

      • If battery voltage is applied for more than 3 seconds, the intake air control valve actuator may be damaged.

      • Do not allow the lead wires to contact the other terminals.

    7. A01G8Z3E01
      Text in Illustration
      *A w/ TCV
      *B w/o TCV

      Remove the bolt and separate the wire harness.

    8. Disengage the 2 wire harness clamps and disconnect the intake air control valve actuator connector (w/ TCV).

    9. Disengage the 2 wire harness clamps (w/o TCV).

    10. A01G8IH

      Remove the 6 bolts and intake manifold (w/ TCV).

      Note

      The tumble control valves may be damaged if they are not closed before removing the intake manifold.

      Tech Tips

      Connect the battery to the terminals of the intake air control valve actuator to operate the motor and close the tumble control valves Click here.

    11. A01G81V

      Remove the 6 bolts and intake manifold (w/o TCV).

    12. A01G63C

      Remove the intake manifold gasket from the intake manifold (w/ TCV).

    13. A01G4DR

      Remove the intake manifold gasket from the intake manifold (w/o TCV).

    14. A01G7TV

      Disconnect the 2 vacuum hoses from the intake manifold to remove the No. 1 check valve.

    15. A01G5J4E01

      Remove the bolt and wire harness clamp bracket from the intake manifold.