INTAKE MANIFOLD > REMOVAL

for Preparation Click here



1. REMOVE WINDSHIELD WIPER MOTOR AND LINK

  1. Remove the windshield wiper motor and link (Click here).



2. DRAIN ENGINE COOLANT (w/ Water Inlet Drain Cock Plug)



A198899E01


Text in Illustration 
*1
Water Filler Cap Sub-assembly
*3
Radiator Drain Cock Plug
*2
Water Inlet Drain Cock Plug
-
-

CAUTION:
To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

  1. Loosen the radiator drain cock plug.

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

  1. Remove the water filler cap sub-assembly.



    A201664E01

  1. Connect the hose to the water inlet drain cock plug.
    Text in Illustration 
    *1
    		Hose
    *2
    		Water Inlet Clip

  1. Remove the water inlet clip.



    A201666

  1. Pull out the water inlet drain cock plug.



3. DRAIN ENGINE COOLANT (w/o Water Inlet Drain Cock Plug)


A236548E01

CAUTION:
To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

  1. Loosen the radiator drain cock plug.
    Text in Illustration 
    *1
    		Water Filler Cap Sub-assembly
    *2
    		Radiator Drain Cock Plug

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

  1. Remove the water filler cap sub-assembly.



4. REMOVE BATTERY (for LHD)


A191829

  1. Disconnect the cables from the battery terminals.

  1. Remove the 2 nuts and the battery clamp.

  1. Remove the battery.



5. REMOVE EFI FUEL PIPE CLAMP (for LHD)


    A199568

  1. Remove the EFI fuel pipe clamp.



6. DISCONNECT FUEL TUBE SUB-ASSEMBLY (for LHD)


A199569E01

  1. Pinch the tube connector and then pull out the fuel pipe.

    NOTICE:
    1. Check that there is no dirt or mud on the pipe and around the connector before disconnecting the fuel tube connector. Clean it if necessary.
    2. If the connector and the pipe are stuck, push and pull on the connector to release them while pinching the retainer. Do not use any tools.



7. DISCONNECT INLET HEATER WATER HOSE (for LHD)


I104819

  1. Slide the clip and disconnect the heater water inlet hose from the air conditioning unit.



8. DISCONNECT OUTLET HEATER WATER HOSE (for LHD)


I104820

  1. Slide the clip and disconnect the heater water inlet hose from the air conditioning unit.



9. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

  1. Remove the throttle with motor body assembly (Click here).



10. REMOVE INTAKE MANIFOLD


    A201008

  1. Disconnect the vacuum switching valve connector.

  1. Loosen the hose clamp and disconnect the fuel vapor feed hose.

  1. Disconnect the 2 water by-pass hoses from the intake manifold.



    A201013

  1. Disconnect the vacuum sensor connector.

  1. Disengage the 4 wire harness clamps and separate the wire harness from the intake manifold.

  1. Remove the 2 bolts.



    A200982

  1. Loosen the hose clamp and disconnect the union to check valve hose.

  1. Disconnect the vacuum hose.

  1. Loosen the hose clamp and disconnect the ventilation hose.



    A200984

  1. Remove the 2 bolts, 2 nuts, and intake manifold.



    A200986

  1. Remove the gasket from the intake manifold.



    A200985

  1. Remove the stud bolt from the intake manifold.



11. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY


A201019

  1. Remove the screw and the vacuum sensor.



12. REMOVE DUTY VACUUM SWITCHING VALVE


A201007

  1. Remove the bolt.

  1. Separate the fuel vapor feed hose and remove the vacuum switching valve.



13. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR


A201012

  1. Remove the nut, the 2 bolts and the intake manifold insulator.

  1. Remove the gasket from the cylinder head.



14. REMOVE EGR VALVE ASSEMBLY


    A199578

  1. Disconnect the EGR valve connector.

  1. Separate the water by-pass hose.



    A199580

  1. Rotate the EGR valve to avoid contact with the delivery pipe, and remove the EGR valve.

  1. Remove the gasket.