INTAKE MANIFOLD REMOVAL

PROCEDURE

  1. DISCHARGE FUEL SYSTEM PRESSURE

  2. PRECAUTION

    Note:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work.

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  3. REMOVE DECK BOARD ASSEMBLY

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  4. REMOVE BATTERY SERVICE COVER

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  5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  6. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

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  7. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

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  8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    1. for LHD:

      1. Disconnect the connector.

      2. Detach the 4 clamps and disconnect the wire harness.

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

        A365426

    2. for RHD:

      1. Detach the 2 clamps and disconnect the wire harness.

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

        A365427

  9. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  10. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  11. REMOVE EGR VALVE ASSEMBLY (w/ EGR System)

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  12. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR

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  13. DISCONNECT ENGINE WIRE

    1. A309435

      Disconnect the heated oxygen sensor connector.

    2. A309436

      Detach the 6 clamps and disconnect the engine wire.

  14. DISCONNECT INTAKE MANIFOLD

    1. A316733

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

    2. A257344

      Remove the 6 bolts and disconnect the intake manifold.

  15. DISCONNECT NO. 1 EGR PIPE (w/ EGR System)

    1. A313564

      Remove the nut and bolt, and then disconnect the No. 1 EGR pipe from the EGR cooler assembly.

    2. Remove the 2 bolts and disconnect the No. 1 EGR pipe.

    3. Remove the gasket from the No. 1 EGR pipe.

  16. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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  17. REMOVE FUEL DELIVERY PIPE

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  18. REMOVE INTAKE MANIFOLD

    1. Remove the intake manifold from the vehicle.

    2. A257345

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

    3. A257346

      Remove the bolt and wiring harness clamp bracket.

    4. A257347

      Remove the vacuum hose from the intake manifold.

    5. A258678

      Slide the clamp and disconnect the purge line hose from the intake manifold.

  19. REMOVE INTAKE FLANGE (w/o EGR System)

    1. A326435

      Remove the engine cover joint from the intake flange.

    2. Remove the 3 bolts and intake flange.

    3. Remove the gasket from the intake manifold.