INTAKE MANIFOLD REMOVAL


  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK


    1. Remove the windshield wiper motor and link Click here.

  2. DRAIN ENGINE COOLANT (w/ Water Inlet Drain Cock Plug)

    A011ASWE01
    Text in Illustration
    *1 Water Filler Cap Sub-assembly *3 Radiator Drain Cock Plug
    *2 Water Inlet Drain Cock Plug - -

    CAUTION:

    To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. Remove the water filler cap sub-assembly.

    3. A0119WWE01
      Text in Illustration
      *1 Hose
      *2 Water Inlet Clip

      Connect the hose to the water inlet drain cock plug.

    4. Remove the water inlet clip.

    5. A0117FS

      Pull out the water inlet drain cock plug.

  3. DRAIN ENGINE COOLANT (w/o Water Inlet Drain Cock Plug)

    A011776E01
    Text in Illustration
    *1 Water Filler Cap Sub-assembly
    *2 Radiator Drain Cock Plug

    CAUTION:

    To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. Remove the water filler cap sub-assembly.

  4. REMOVE BATTERY (for LHD)

    A011AIM

    1. Disconnect the cables from the battery terminals.

    2. Remove the 2 nuts and the battery clamp.

    3. Remove the battery.

  5. REMOVE EFI FUEL PIPE CLAMP (for LHD)


    1. A011A8R

      Remove the EFI fuel pipe clamp.

  6. DISCONNECT FUEL TUBE SUB-ASSEMBLY (for LHD)

    A011BLSE01

    1. Pinch the tube connector and then pull out the fuel pipe.

      Note


      • Check that there is no dirt or mud on the pipe and around the connector before disconnecting the fuel tube connector. Clean it if necessary.

      • If the connector and the pipe are stuck, push and pull on the connector to release them while pinching the retainer. Do not use any tools.

  7. DISCONNECT INLET HEATER WATER HOSE (for LHD)

    A011926

    1. Slide the clip and disconnect the heater water inlet hose from the air conditioning unit.

  8. DISCONNECT OUTLET HEATER WATER HOSE (for LHD)

    A011AZM

    1. Slide the clip and disconnect the heater water inlet hose from the air conditioning unit.

  9. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY


    1. Remove the throttle with motor body assembly Click here.

  10. REMOVE INTAKE MANIFOLD


    1. A011BVW

      Disconnect the vacuum switching valve connector.

    2. Loosen the hose clamp and disconnect the fuel vapor feed hose.

    3. Disconnect the 2 water by-pass hoses from the intake manifold.

    4. A0117YN

      Disconnect the vacuum sensor connector.

    5. Disengage the 4 wire harness clamps and separate the wire harness from the intake manifold.

    6. Remove the 2 bolts.

    7. A0116VX

      Loosen the hose clamp and disconnect the union to check valve hose.

    8. Disconnect the vacuum hose.

    9. Loosen the hose clamp and disconnect the ventilation hose.

    10. A011BHX

      Remove the 2 bolts, 2 nuts, and intake manifold.

    11. A011947

      Remove the gasket from the intake manifold.

    12. A0117G9

      Remove the stud bolt from the intake manifold.

  11. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY

    A011AG9

    1. Remove the screw and the vacuum sensor.

  12. REMOVE DUTY VACUUM SWITCHING VALVE

    A01193H

    1. Remove the bolt.

    2. Separate the fuel vapor feed hose and remove the vacuum switching valve.

  13. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    A0117GE

    1. Remove the nut, the 2 bolts and the intake manifold insulator.

    2. Remove the gasket from the cylinder head.

  14. REMOVE EGR VALVE ASSEMBLY


    1. A0118LA

      Disconnect the EGR valve connector.

    2. Separate the water by-pass hose.

    3. A011BD9

      Rotate the EGR valve to avoid contact with the delivery pipe, and remove the EGR valve.

    4. Remove the gasket.