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

    Note

    Do not remove the radiator cap sub-assembly, cylinder block drain cock plugs and radiator drain cock plug while the engine and radiator 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 2 cylinder block drain cock plugs.

    3. Remove the radiator cap sub-assembly.

      A011TE6E01
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Cylinder Block Drain Cock Plug
      *3 Radiator Drain Cock Plug *4 Air Drain Cock Plug

      Tech Tips

      Collect the 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

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

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

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  7. REMOVE V-BANK COVER SUB-ASSEMBLY

    1. 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.

      A011RX1

      Note

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

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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

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    2. Disconnect the 3 hoses.

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    3. Separate the ventilation hose.

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

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    5. Release the 2 clamps and remove the air cleaner cap with hose.

  9. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

    1. Disconnect the ventilation hose.

      A011T1CE01
      Text in Illustration
      *A Type A
      *B Type B

    2. Disconnect the hose clamp and union to check valve hose.

    3. Disconnect the connector and wire harness clamp.

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    4. Disconnect the 2 water by-pass hoses and fuel vapor feed hose.

    5. Disconnect the connector from the intake air control valve assembly.

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    6. Remove the bolt and vacuum hose clamp.

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

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

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

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    10. Using a 5 mm socket hexagon wrench, remove the 4 bolts.

    11. Remove the intake air surge tank assembly and 3 gaskets.

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  10. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting Stay Side)

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

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

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

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  12. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    1. Remove the No. 2 fuel pipe clamp.

      A011TL3E09
      Text in Illustration
      *1 No. 2 Fuel Pipe Clamp
      *2 Fuel Tube Connector
      *3 Nylon Tube
      *4 O-ring
      *5 Fuel Pipe
      A011T1X Pinch
      A011V7Q Pull

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

      Note

      • Check that there is no dirt or other foreign objects around the fuel tube connector when disconnecting it. Clean the fuel tube connector as necessary.

      • It is necessary to prevent dirt or foreign objects from entering the fuel tube connector. If dirt or foreign objects get in the fuel tube connector, the O-rings may not seal properly.

      • Only disconnect the fuel tube connector by hand.

      • Do not bend, kink or twist the nylon tubes.

      • Protect the fuel tube connector by covering it with plastic bags.

      • If the fuel pipe and the fuel tube connector are stuck, carefully try wiggling or pushing and pulling on the fuel tube connector to release it. Pull the fuel tube connector off carefully.

  13. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

    1. Disconnect the 6 fuel injector connectors.

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    2. Remove the 5 bolts and fuel delivery pipe sub-assembly together with the 6 fuel injectors.

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      Note

      Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

    3. Remove the 6 injector vibration insulators from the intake manifold.

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  14. REMOVE INTAKE MANIFOLD

    1. Remove the 6 bolts, 4 nuts and intake manifold.

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      Text in Illustration
      *A Type A
      *B Type B

    2. Remove the 2 gaskets.

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