INTAKE MANIFOLD REMOVAL


  1. REMOVE AIR CLEANER ASSEMBLY


    1. Remove the air cleaner assembly Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Tech Tips

    Click here.

  3. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. A019KAPE01
      Text in Illustration
      *1 for RHD:
      *2 for LHD:

      Disconnect the union to check valve hose.

    2. A019JMB

      Disconnect the throttle body assembly connector and wire harness clamp.

    3. A019N1A

      Disconnect the vacuum hose clamp and fuel vapor feed hose.

    4. A019MBG

      Disconnect the 2 water by-pass hoses.

    5. A019M0E

      Disconnect the ventilation hose and vacuum hose.

    6. A019KEL

      Disconnect the connector from the intake air control valve assembly.

    7. A019NBS

      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. A019MTQ

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

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

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

  4. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A019MSW

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

  5. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A019M4UE01

      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.

  6. REMOVE FUEL INJECTOR ASSEMBLY


    1. A019L6B

      Disconnect the 6 fuel injector connectors.

    2. A019PEL

      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. A019L71E01

      Remove the 6 injector vibration insulators from the intake manifold.

    4. A019PB3

      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. A019LOEE03
      Text in Illustration
      *1 O-ring

      Remove the 6 O-rings from the injectors.

  7. REMOVE INTAKE MANIFOLD


    1. A019NJI

      Remove the 6 bolts, 4 nuts, intake manifold and 2 intake manifold to head gaskets.