INTAKE MANIFOLD REMOVAL

PROCEDURE

  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  2. REMOVE FRONT NO. 1 VENTILATOR SEAL (for LHD)

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  3. REMOVE FRONT NO. 1 VENTILATOR SEAL (for RHD)

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  4. REMOVE FRONT AIR SHUTTER SEAL RH (for LHD)

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  5. REMOVE FRONT AIR SHUTTER SEAL RH (for RHD)

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  6. REMOVE OUTER COWL TOP PANEL (for LHD)

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  7. REMOVE OUTER COWL TOP PANEL (for RHD)

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  8. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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  9. REMOVE VACUUM SENSOR ASSEMBLY

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  10. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE

    1. A322671

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

  11. DISCONNECT VACUUM HOSE ASSEMBLY

    1. A322672C01

      *a

      Retainer
      V100135

      Pinch
      V100136

      Pull

      Pinch the retainer of the vacuum hose assembly connector, and then pull the vacuum hose assembly connector off of the intake manifold.

      Note:

      Be sure to disconnect the vacuum hose assembly connector by hand.

    2. Disengage the vacuum hose assembly from the hose clamp.

    3. A322673

      Disengage the vacuum hose assembly from the hose clamp. (for RHD)

  12. SEPARATE CLUTCH CABLE BRACKET

    1. A322678

      Remove the 2 nuts and separate the clutch cable bracket from the vehicle body.

  13. DISENGAGE WATER BY-PASS HOSE ASSEMBLY

    1. A327414

      Disengage the water by-pass hose assembly from the 4 hose clamps.

  14. REMOVE FUEL HOSE BRACKET

    1. A322675

      Disengage the fuel tube sub-assembly from the hose clamp.

    2. Remove the bolt and fuel hose bracket from the intake manifold.

  15. REMOVE WIRE HARNESS CLAMP BRACKET

    1. A322676

      Disengage the 3 wire harness clamps.

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

    3. Remove the bolt and wire harness clamp bracket from the cylinder head sub-assembly.

  16. REMOVE INTAKE MANIFOLD (for LHD)

    1. A322677

      Disengage the 2 wire harness clamps from the intake manifold.

    2. A324767

      Raise the lever while pushing the lock on the lever, and disconnect the ECM connector.

      Note:

      After disconnecting the ECM connectors, make sure that dirt, water or other foreign matter does not contact the connecting parts of the ECM connectors.

    3. Disengage the wire harness clamp.

    4. A322679C01
      V100135

      Bolt
      V100136

      Nut

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

  17. SEPARATE INTAKE MANIFOLD (for RHD)

    1. A322677

      Disengage the 2 wire harness clamps from the intake manifold.

    2. A322679C01
      V100135

      Bolt
      V100136

      Nut

      Remove the 2 bolts and 2 nuts and separate the intake manifold.

  18. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for RHD)

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  19. REMOVE INTAKE MANIFOLD (for RHD)

    1. Remove the intake manifold from the cylinder head sub-assembly.

  20. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

    1. A322692

      Remove the No. 1 intake manifold to head gasket from the intake manifold.

  21. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    1. A322680C01
      V100135

      Bolt
      V100136

      Nut

      Remove the 2 bolts, nut and No. 1 intake manifold insulator from the EGR valve assembly.

    2. Remove the No. 2 intake manifold to head gasket from the cylinder head sub-assembly.

  22. REMOVE EGR VALVE ASSEMBLY

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