INTAKE MANIFOLD REMOVAL


  1. REMOVE AIR CLEANER ASSEMBLY WITH HOSE


    1. Remove the air cleaner assembly with hose Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Tech Tips

    Click here.

  3. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. A01ND1X

      Disconnect the throttle body assembly connector and wire harness clamp.

    2. A01NF4U

      Disconnect the fuel vapor feed hose.

    3. A01NG7C

      Disconnect the 2 water by-pass hoses.

    4. A01NHMY

      Disconnect the 5 clamps and separate the main wire.

    5. A01NGGD

      Disconnect the ventilation hose.

    6. A01NCZR

      Disconnect the connector from the manifold absolute pressure sensor.

    7. A01NHZZ

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

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

    9. A01NE93

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

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

    11. A01NDLR

      Remove the intake air surge tank assembly and 3 air surge tank to intake manifold gaskets.

  4. REMOVE NO. 2 EGR PIPE


    1. A01NG7P

      Remove the 2 nuts, 2 bolts, No. 2 EGR pipe and 2 gaskets. (Type A)

    2. A01NFDI

      Remove the 2 nuts, 2 bolts, No. 2 EGR pipe and 2 gaskets. (Type B)

  5. REMOVE EGR DELIVERY CHAMBER


    1. A01NCSW

      Disconnect the 2 water hoses and connector.

    2. A01NES0

      Remove the EGR delivery chamber.

    3. A01NGB1

      Remove the No. 2 intake manifold gasket.

  6. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A01NGMS

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

  7. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A01NFDW

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

  8. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01NFNFE01

      Remove the No. 2 fuel pipe clamp.

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

      Note


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

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

      • Only disconnect the quick connector by hand.

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

      • Protect the connector by covering it with a plastic bag.

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

  9. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01NGCM

      Disconnect the 6 fuel injector connectors.

    2. A01NFMA

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

      Note

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

    3. A01NE85E01

      Remove the 6 injector vibration insulators from the intake manifold.

    4. A01NE3N

      Pull out the fuel injectors from the fuel delivery pipe.

      Note

      If the injectors are to be reused, reinstall them to the same cylinder they came from.

    5. A01NHAPE03
      Text in Illustration
      *1 O-ring

      Remove the 6 O-rings from the injectors.

  10. REMOVE INTAKE MANIFOLD


    1. A01NE99

      Remove the 6 bolts, 4 nuts and intake manifold.

    2. A01NE8S

      Remove the 2 intake manifold gaskets.