INTAKE MANIFOLD REMOVAL

PROCEDURE


  1. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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  2. DISCONNECT NO. 2 TURBO WATER HOSE

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  3. DISCONNECT NO. 1 VACUUM TRANSMITTING HOSE

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  4. DISCONNECT NO. 8 WATER BY-PASS HOSE

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  5. DISCONNECT NO. 9 WATER BY-PASS HOSE

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  6. SEPARATE HEATER WATER PUMP ASSEMBLY

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  7. DISCONNECT ENGINE WIRE

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  8. DISCONNECT NO. 1 AIR TUBE

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  9. DISCONNECT INTERCOOLER ASSEMBLY

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  10. REMOVE PURGE VALVE (PURGE VSV)


  11. REMOVE INTERCOOLER RESERVE TANK ASSEMBLY


    1. A01R5VFC01
      *1 No. 3 Intercooler Cooling Water Hose
      *2 No. 4 Intercooler Cooling Water Hose
      *3 Fuel Tube Sub-assembly

      Disengage the 2 fuel tube sub-assemblies from the intercooler reserve tank assembly.

    2. Slide the clip and disconnect the No. 3 intercooler cooling water hose from the No. 2 water by-pass pipe.

    3. Remove the 2 bolts and intercooler reserve tank assembly from the intercooler reserve tank bracket.

    4. Slide the clip and disconnect the No. 4 intercooler cooling water hose from the intercooler reserve tank assembly.

  12. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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  13. REMOVE AIR CLEANER HOSE ASSEMBLY

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  14. REMOVE FUEL HOSE BRACKET


    1. A01R4PJ

      Disengage the clamp.

    2. Disengage the 2 fuel tube sub-assemblies from the fuel hose bracket.

    3. Remove the bolt and fuel hose bracket from the intake manifold.

  15. REMOVE NO. 2 VENTILATION HOSE


    1. A01R44L

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

  16. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A01R3X1C01
      *1 No. 1 Turbo Water Hose
      *2 No. 2 Turbo Water Hose

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

    2. A01R6SP

      Remove the 2 bolts and No. 2 water by-pass pipe from the intake manifold.

  17. DISCONNECT INLET HEATER WATER HOSE A

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  18. DISCONNECT OUTLET HEATER WATER HOSE A

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  19. DISCONNECT ENGINE WIRE


    1. A01R7FGC01
      B0073AQ Bolt
      B0077IM Connector

      Remove the 2 bolts.

    2. Disconnect the 6 connectors.

    3. Disengage the 2 clamps.

    4. A01R3ZD

      Disconnect the 5 connectors.

  20. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01R7H8

      Disengage the clamp.

    2. Slide the clip and disconnect the No. 3 water by-pass hose from the water outlet sub-assembly.

  21. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01R55X

      Disengage the clamp from the cylinder head cover sub-assembly.

    2. Disconnect the No. 2 vacuum transmitting hose assembly from the vacuum pump assembly.

  22. DISCONNECT VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01R7BE

      Disengage the 4 clamps and disconnect the vacuum transmitting hose assembly from the cylinder head cover sub-assembly.

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

  23. DISCONNECT INLET HEATER WATER HOSE B


    1. A01R6E6

      Slide the clip and disconnect the inlet heater water hose B from the No. 5 water by-pass pipe.

  24. REMOVE INTAKE MANIFOLD


    1. A01R5WMC01
      B0073AQ Bolt
      B0077IM Nut

      Remove the 4 bolts, 2 nuts and intake manifold from the cylinder head sub-assembly and cylinder block sub-assembly.

    2. A01R3TBC01
      B0073AQ Bolt
      B0077IM Nut

      Remove the 2 bolts, nut and No. 5 water by-pass pipe from the intercooler support bracket sub-assembly.

    3. A01R679

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

      Note

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

    4. A01R6WU

      Remove the 2 intake manifold gaskets from the intake manifold.

  25. REMOVE NO. 2 TURBO PRESSURE SENSOR


    1. A01R79A

      Disengage the No. 1 vacuum transmitting hose assembly from the intake manifold.

    2. Remove the bolt and No. 2 turbo pressure sensor from the intake manifold.

  26. REMOVE NO. 2 FUEL VAPOR FEED HOSE


    1. A01R7GI

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

  27. REMOVE BRACKET


    1. A01R789

      Remove the bolt and bracket from the intake manifold.

  28. REMOVE NO. 3 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01R39L

      Disengage the 2 clamps.

    2. A01R5JM

      Remove the No. 3 vacuum transmitting hose assembly from the vacuum surge tank and vacuum regulating valve assembly.

  29. REMOVE NO. 1 TURBO PRESSURE SENSOR


    1. A01R3TP

      Remove the bolt and No. 1 turbo pressure sensor from the intake manifold.

  30. REMOVE VACUUM REGULATING VALVE ASSEMBLY


    1. A01R6WS

      Remove the 2 bolts and vacuum regulating valve assembly from the intake manifold.

  31. REMOVE NO. 4 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01R4ZA

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

  32. REMOVE VACUUM SURGE TANK


    1. A01R6B3

      Remove the 3 bolts and vacuum surge tank from the intake manifold.