Removal
Intake Manifold Components:
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY
CAUTION (W / Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.
2. DRAIN ENGINE COOLANT
3. DISCONNECT ACCELERATOR CABLE FROM THROTTLE LINKAGE
4. (A/T) DISCONNECT THROTTLE CABLE FROM THROTTLE LINKAGE
Air Cleaner Hose:
5. REMOVE AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE
(a) Disconnect the volume air flow meter connector.
(b) Disconnect the coil cord clamp.
(c) Disconnect the air hoses.
(d) Loosen the air cleaner hose clamp bolt.
(e) Disconnect the air cleaner cap clips.
(f) Remove the air cleaner cap and volume air flow meter together with the air cleaner hose.
V-Bank Cover:
6. REMOVE V-BANK COVER
Using a 5 mm hexagon wrench, remove the two nuts and V-bank cover.
Emission Control Valve Set Removal:
7. REMOVE EMISSION CONTROL VALVE SET
(a) Disconnect the EGR gas temp. sensor connector clamp from the emission control valve set.
(b) Disconnect the two vacuum hoses of the fuel pressure control VSV.
(c) Disconnect the two vacuum hoses of the IACV VSV.
(d) Disconnect the two VSV connectors.
(e) Remove the two bolts and emission control valve set.
Intake Air Chamber Hoses:
8. DISCONNECT HOSES
(a) Brake booster vacuum hose
(b) PS air hose
(c) PCV hose
(d) IACV vacuum hose
9. DISCONNECT GROUND STRAPS
Remove the nut and disconnect the two ground straps.
10. DISCONNECT COLD START INJECTOR CONNECTOR
No. 2 Fuel Pipe:
11. DISCONNECT COLD START INJECTOR PIPE (NO.2 FUEL PIPE)
(a) Put a suitable container or shop towel under the injector pipe.
(b) Remove the union bolt and two gaskets. and disconnect the injector pipe.
HINT: Slowly loosen the union bolt.
Air Intake Chamber Stay:
12. REMOVE NO.1 ENGINE HANGER AND AIR INTAKE CHAMBER STAY
(a) Remove the two bolts and No.1 engine hanger.
(b) Remove the two bolts and air intake chamber stay.
13. REMOVE EGR PIPE
(a) Loosen the union nut.
(b) Remove the two bolts and EGR pipe.
14. DISCONNECT HYDRAULIC MOTOR PRESSURE PIPE
Remove the bolt and disconnect the hydraulic pressure pipe from the air intake chamber.
Connector And Hoses:
15. REMOVE AIR INTAKE CHAMBER
(a) Disconnect the three emission control vacuum hoses.
(b) Disconnect the two water by-pass hoses.
(c) (Calif. only) Disconnect the EGR gas temp. sensor connector.
Air Intake Chamber Removal:
(d) Disconnect the throttle position sensor connector.
(e) Disconnect the IAC valve connector.
(f) Disconnect the IAC valve air hose.
(g) Disconnect the PS air hose.
Air Intake Chamber Removal:
(h) Using 8 mm hexagon wrench, remove the two bolts, nuts, air intake chamber and gasket.
Fuel Lines:
16. DISCONNECT FUEL INLET AND RETURN HOSES
(a) Disconnect the fuel return hoses from the No.1 fuel pipe.
(b) Disconnect the fuel inlet hose from the fuel filter.
17. DISCONNECT INJECTOR CONNECTORS
No. 2 Fuel Pipe:
18. REMOVE NO.2 FUEL PIPE
(a) Disconnect the vacuum hose.
(b) Remove the two union bolts, four gaskets and No.2 fuel pipe.
Fuel Rail:
19. REMOVE LH DELIVERY PIPES AND INJECTORS
(a) Disconnect the fuel hose from the No.1 fuel pipe.
(b) Remove two bolts and LH delivery pipe together with the three injectors.
NOTICE: Be careful not to drop the injectors, when
removing the LH delivery pipe.
(c) Pull out the three injectors from the LH delivery pipe.
(d) Remove the two spacers from the intake manifold.
Air Pipe:
20. REMOVE AIR PIPE WITH HOSES
(a) Disconnect the two air hoses.
(b) Remove the bolts and air pipe with hoses.
Fuel Rail:
21. REMOVE RH DELIVERY PIPE AND INJECTORS
(a) Remove three bolts and RH delivery pipe together with the three injectors.
NOTICE: Be careful not to drop the injectors, when removing the LH delivery pipe.
(b) Pull out the three injectors from the RH delivery pipe.
(c) Remove the two spacers from the intake manifold.