INTAKE MANIFOLD REMOVAL

PROCEDURE

1. REMOVE FUEL DELIVERY PIPE

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2. DRAIN ENGINE COOLANT

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3. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

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4. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

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5. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

   1. 

      Detach the clamp and disconnect the wire harness from the outer cowl top panel sub-assembly.

   2. Remove the 13 bolts and outer cowl top panel sub-assembly.

      

6. REMOVE NO. 1 HOSE TO HOSE TUBE

   1. 

      Slide the 2 clamps and disconnect the 2 hoses from the No. 1 hose to hose tube.

   2. Remove the 2 nuts and No. 1 hose to hose tube.

7. DISCONNECT HEATER HOSE

   1. 

      Slide the clamp and disconnect the inlet heater water hose from the heater radiator unit.

   2. Slide the clamp and disconnect the outlet heater water hose from the heater radiator unit.

8. DISCONNECT WIRE HARNESS

   1. 

      Disconnect the connector, detach the clamp and disconnect the 2 vacuum hoses, and then remove the vacuum switching valve.

   2. 

      Detach the 2 clamps.

   3. Remove the 2 bolts and wiring harness clamp bracket.

   4. 

      Remove the bolt and disconnect the bracket.

   5. 

      *a	Component without harness connected (Tumble Control Valve)

      for TCV:

      Apply battery voltage to the terminals of the connector to close the tumble control valves.

      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 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. 

      for TCV:

      Disconnect the intake air control valve actuator connector.

   7. 

      Detach the clamp and disconnect the wire harness.

9. DISCONNECT NO. 2 PCV HOSE

   1. 

      Slide the clamp and disconnect the No. 2 PCV hose from the intake manifold.

10. REMOVE INTAKE MANIFOLD

    1. 

       Remove the 6 bolts and intake manifold.

       Note:

       The valves may be damaged if they are not closed before removing the intake manifold.

    2. Remove the gasket from the intake manifold.

    3. Remove the 2 vacuum hoses from the intake manifold.

11. REMOVE UNION TO CONNECTOR TUBE HOSE

    1. 

       Slide the clamp and remove the union to connector tube hose from the intake manifold.

12. REMOVE CHECK VALVE

    1. 

       Disconnect the 2 vacuum hoses from the intake manifold and remove the check valve.

    2. Remove the 2 vacuum hoses from the check valve.

13. REMOVE PURGE LINE HOSE

    1. 

       Disconnect the purge line hose from the clamp.

    2. Slide the clamp and remove the purge line hose from the intake manifold.

14. REMOVE INTAKE AIR CONTROL VALVE ACTUATOR (for TCV)

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