INTAKE MANIFOLD REMOVAL


  1. PRECAUTION

    Note

    After turning the ignition 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 RHD)


    1. A01EZ4M

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

    2. A01EZ0G

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

  6. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. A01EVIB

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

    2. A01EYMF

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

  7. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  8. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. A01EXG5

      Disconnect the union to connector tube hose and wire harness clamp.

    2. Disconnect the 2 vacuum hoses and connector.

    3. Remove the bolt and vacuum switching valve assembly.

  9. DISCONNECT NO. 2 VENTILATION HOSE


    1. A01EYK5

      Disconnect the No. 2 ventilation hose from the intake manifold.

  10. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. A01EY2R

      Disconnect the union to connector tube hose from the intake manifold.

  11. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01ETBOE01

      Remove the No. 1 fuel pipe clamp.

    2. A01EXSEE01
      Text in Illustration
      *1 Fuel Pipe
      *2 Fuel Tube Connector
      *3 Nylon Tube
      *4 O-ring
      *5 Retainer
      A01EUL1 Pinch
      A01ETOA Pull

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

      Note


      • Check for foreign matter on the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe.

      • Do not use any tools to separate the fuel tube connector and fuel pipe.

      • Do not forcefully bend, kink or twist the nylon tube.

      • Keep the fuel tube connector and fuel pipe free from foreign matter.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

      • Put the fuel tube connector and fuel pipe in plastic bags to prevent damage and contamination.

    3. Remove the fuel tube sub-assembly from the fuel hose clamp.

  12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01ETSZ

      Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors.

      Note

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

    2. A01EYWY

      Remove the 2 fuel delivery spacers from the cylinder head.

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

  13. REMOVE INTAKE MANIFOLD


    1. A01EW2L

      Remove the 2 bolts and 2 wire harness clamp brackets.

    2. A01EUH1

      Disconnect the fuel vapor feed hose.

    3. Disconnect the 3 wire harness clamps and connector.

    4. Remove the bolt and wire harness clamp bracket.

    5. A01EY22

      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 actuator may be damaged.

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

    6. A01EY87E01

      Remove the bolt and separate the wire harness.

    7. Disconnect the 2 wire harness clamps and intake air control valve actuator connector (w/ TCV).

    8. Disconnect the 2 wire harness clamps (w/o TCV).

      Text in Illustration
      *A w/ TCV
      *B w/o TCV
    9. A01ETJY

      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 actuator to operate the motor and close the valves Click here.

    10. A01ETCB

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

    11. A01ESUQ

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

    12. A01EXBH

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

    13. A01EXWK

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

    14. A01EYEZ

      Remove the bolt and wire harness clamp bracket.