INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during intake manifold removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effects/Inoperative when Necessary Procedure not Performed Link

  • Replacement of throttle body with motor assembly

  • Cleaning the deposits from the throttle body with motor assembly

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

Click here for Rear Air Fuel Ratio Sensor

Click here for Rear Heated Oxygen Sensor

PROCEDURE


  1. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  2. REMOVE INTERCOOLER ASSEMBLY

    Click here

  3. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

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

    Click here

  5. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  6. REMOVE PURGE VALVE (PURGE VSV)

    Click here

  7. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  8. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

  9. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B007Y0GC01
      *a Air Cleaner Support

      Remove the 2 bolts and air cleaner case sub-assembly.

      Note

      Make sure the air cleaner support remains attached to the vehicle body.

  10. DISCONNECT NO. 5 INTERCOOLER COOLING WATER HOSE


    1. B007XCG

      Slide the clip and disconnect the No. 5 intercooler cooling water hose from the No. 3 Intercooler cooling water pipe.

  11. DISCONNECT NO. 6 INTERCOOLER COOLING WATER HOSE


    1. B007ZND

      Slide the clip and disconnect the No. 6 intercooler cooling water hose from the No. 2 Intercooler cooling water pipe.

  12. DISCONNECT ENGINE WIRE


    1. B007XG6C02
      B007WXX Bolt
      B00803L Connector

      Disconnect the 3 sensor wire connectors.

    2. Disengage the wire harness clamp from the wire harness bracket.

    3. Remove the 2 bolts from the wire harness bracket.

    4. B007X18

      Remove the bolt and disconnect the sensor wire from the intercooler support bracket sub-assembly.

    5. Disengage the clamp and remove the sensor wire from the intercooler support bracket sub-assembly.

    6. B007ZI1C01
      B007WXX Bolt
      B00803L Connector

      Disconnect the 7 connectors.

    7. Disengage the 4 wire harness clamps.

    8. Remove the bolt.

    9. B007XGYC01
      B007WXX Bolt
      B00803L Connector
      B007X40 Ground Bolt

      Disconnect the 5 connectors.

    10. Disengage the 4 wire harness clamps.

    11. Remove the ground bolt.

    12. Remove the bolt.

  13. REMOVE NO. 2 WATER BY-PASS PIPE


    1. B007ZB0

      Remove the 3 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly and bracket.

  14. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. B007ZF9

      Disconnect the No. 2 vacuum transmitting hose assembly from the vacuum pump assembly and cylinder head cover sub-assembly.

  15. REMOVE NO. 1 TURBO PRESSURE SENSOR

    Click here

  16. DISCONNECT VACUUM TRANSMITTING HOSE ASSEMBLY


    1. B007ZWZ

      Disconnect the vacuum transmitting hose assembly from the vacuum regulating valve assembly.

  17. REMOVE NO. 2 VENTILATION HOSE


    1. B007WQB

      Slide the 2 clips and remove the No. 2 ventilation hose from the intake manifold and PCV valve (ventilation valve sub-assembly).

  18. DISCONNECT WATER BY-PASS HOSE


    1. B007YAAC01
      *1 No. 1 Water By-pass Hose
      *2 No. 2 Water By-pass Hose

      Slide the clip and disconnect the No. 2 water by-pass hose from the No. 1 water by-pass pipe.

    2. Slide the clip and disconnect the No. 1 water by-pass hose from the cylinder head sub-assembly.

  19. REMOVE INTAKE MANIFOLD


    1. B007XZD

      Remove the bolt and disconnect the intercooler support bracket sub-assembly from the cylinder block sub-assembly.

    2. B007Z7DC01
      B007WXX Bolt
      B00803L Nut

      Remove the 3 bolts, 2 nuts and intake manifold from the cylinder head sub-assembly.

    3. B007ZGQ

      Remove the 2 nuts and the manifold thermostat from the intercooler support bracket sub-assembly.

    4. B007ZUM

      Remove the 2 bolts and intercooler support bracket sub-assembly from the intake manifold.

      Note

      Put matchmarks on the intercooler support bracket sub-assembly so that it can be installed to its original position.

    5. B007Z6J

      Remove the bolt and wire harness clamp bracket from the intake manifold.

    6. B007Z2D

      Remove the 2 No. 1 intake manifold to head gaskets from the intake manifold.

  20. REMOVE NO. 2 FUEL VAPOR FEED HOSE


    1. B007YBL

      Slide the clip and remove the No. 2 fuel vapor feed hose from the intake manifold.

  21. REMOVE BRACKET


    1. B007YOO

      Remove the bolt and bracket from the intake manifold.

  22. REMOVE NO. 3 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. B007ZB5

      Disengage the No. 3 vacuum transmitting hose assembly from the intake manifold.

    2. B007ZVQ

      Remove the No. 3 vacuum transmitting hose assembly from the vacuum surge tank and vacuum regulating valve assembly.

  23. REMOVE VACUUM REGULATING VALVE ASSEMBLY


    1. B007Y06

      Disconnect the vacuum regulating valve assembly connector.

    2. Remove the 2 bolts and vacuum regulating valve assembly from the intake manifold.

  24. REMOVE NO. 4 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. B007X0B

      Remove the No. 4 vacuum transmitting hose assembly from the intake manifold and vacuum surge tank.

  25. REMOVE VACUUM SURGE TANK


    1. B007XKU

      Remove the 3 bolts and vacuum surge tank from the intake manifold.