INTAKE MANIFOLD REMOVAL


  1. PRECAUTION

    Note

    After turning the engine 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. DRAIN ENGINE COOLANT

    Note

    Do not remove the radiator cap sub-assembly, cylinder block drain cock plugs and radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

    2. Loosen the cylinder block drain cock plug (for Bank 1).

    3. Loosen the cylinder block drain cock plug (for Bank 2, w/ Cylinder Block Drain Cock Plug).

    4. Remove the radiator cap sub-assembly.

      B000J0SE02
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Cylinder Block Drain Cock Plug (for Bank 1)
      *3 Cylinder Block Drain Cock Plug (for Bank 2, w/ Cylinder Block Drain Cock Plug) *4 Radiator Drain Cock Plug
      *5 Air Drain Cock Plug - -

      Tech Tips

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

  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  6. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. w/ Windshield Deicer System:


      1. B000HLG

        Disengage the 2 clamps.

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

    2. w/ Heated Windshield Defroster System:


      1. B000HSG

        Disengage the 4 clamps.

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

    3. B000KY4

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

    4. B000KRD

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

  7. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. B000NJT

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the retainer on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. B000GYQ

      Disconnect the mass air flow meter connector and wire harness clamp.

    2. B000JRW

      Disconnect the 3 hoses.

    3. Separate the ventilation hose.

    4. B000K4N

      Loosen the hose clamp and separate the air cleaner cap sub-assembly from the throttle with motor body assembly.

    5. Release the 2 clamps and remove the air cleaner cap with hose.

  9. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. B000LRYE01
      Text in Illustration
      *A Type A
      *B Type B

      Disconnect the ventilation hose.

    2. Disconnect the hose clamp and union to check valve hose.

    3. B000KOH

      Disconnect the connector and wire harness clamp.

    4. Disconnect the 2 water by-pass hoses and fuel vapor feed hose.

    5. B000MT6

      Disconnect the connector from the intake air control valve assembly.

    6. B000JEV

      Remove the bolt and vacuum hose clamp.

    7. B000MGD

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

    8. B000MG8

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

    9. B000LIC

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

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

    11. B000MG4

      Remove the intake air surge tank assembly and 3 gaskets.

  10. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting stay Side)


    1. B000L7F

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

  11. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side)


    1. B000J2L

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

  12. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B000MWIE09
      Text in Illustration
      *1 No. 2 Fuel Pipe Clamp
      *2 Fuel Tube Connector
      *3 Nylon Tube
      *4 O-ring
      *5 Fuel Pipe
      B000K70 Pinch
      B000IB9 Pull

      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 fuel tube connector when disconnecting it. Clean the fuel tube connector as necessary.

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

      • Only disconnect the fuel tube connector by hand.

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

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

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

  13. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B000IRH

      Disconnect the 6 fuel injector connectors.

    2. B000J79

      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. B000KQSE01

      Remove the 6 injector vibration insulators from the intake manifold.

  14. REMOVE INTAKE MANIFOLD


    1. B000NBRE01
      Text in Illustration
      *A Type A
      *B Type B

      Remove the 6 bolts, 4 nuts and intake manifold.

    2. B000MG3

      Remove the 2 gaskets.