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 PURGE VALVE (PURGE VSV)

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10. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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11. DISENGAGE WATER BY-PASS HOSE ASSEMBLY

    1. 

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

12. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE

    1. 

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

13. DISCONNECT VACUUM HOSE ASSEMBLY

    1. 

       *a	Retainer
       	Pinch
       	Pull

       for LHD:

       1. 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.

    2. 

       *a	Retainer
       	Pinch
       	Pull

       for RHD:

       1. 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 2 hose clamps.

14. REMOVE FUEL HOSE BRACKET

    1. 

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

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

15. SEPARATE CLUTCH CABLE BRACKET (for Manual Transaxle)

    1. 

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

16. DISCONNECT ENGINE WIRE

    1. 

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

    2. Disengage the 3 wire harness clamps.

    3. 

       Disengage the 2 wire harness clamps and disconnect the engine wire from the intake manifold.

17. REMOVE INTAKE MANIFOLD

    1. 

       for LHD:

       1. 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.

       2. Disengage the wire harness clamp.

    2. 

       Remove the 4 bolts and intake manifold from the cylinder head sub-assembly.

    3. 

       for LHD:

       1. Remove the hose clamp from the intake manifold.

    4. 

       for RHD:

       1. Remove the 2 hose clamps from the intake manifold.

18. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

    1. 

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

19. REMOVE STUD BOLT

    Tip:

    If a stud bolt is deformed or the threads are damaged, replace it.

    1. 

       Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.