Intake Manifold: Service and Repair
REMOVAL1. REMOVE COWL TOP VENTILATOR LOUVER RH
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE V-BANK COVER SUB-ASSEMBLY
4. REMOVE AIR CLEANER INLET COVER
5. REMOVE ENGINE ROOM SIDE COVER RH
6. REMOVE NO.1 AIR CLEANER INLET
7. REMOVE NO.1 ENGINE UNDER COVER
8. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER
9. REMOVE NO.2 ENGINE UNDER COVER
10. DRAIN ENGINE COOLANT
11. REMOVE INTAKE AIR CONNECTOR PIPE
12. REMOVE THROTTLE BODY
13. REMOVE AIR CLEANER ASSEMBLY LH
a. Disconnect the MAF meter connector.
b. Disconnect the 2 clamps and air cleaner cap.
c. Remove the air cleaner element from air cleaner case.
d. Remove the 2 nuts, clip and air cleaner case.
14. REMOVE AIR CLEANER ASSEMBLY RH
a. Disconnect the MAF meter connector.
b. Disconnect the 2 clamps and air cleaner cap.
c. Remove the air cleaner element from air cleaner case.
d. Remove the 2 nuts, clip and air cleaner case.
15. DISCONNECT ENGINE WIRE
HINT: Fix the disconnected harnesses, etc. with tape or equivalent so that they do not interfere.
a. Disconnect the engine wire harness connector.
HINT: To disconnect the injector driver connectors, push the claw downward and move the lock lever to release the lock.
b. Remove the nut, and disconnect the +B terminal of the generator assembly.
c. Using a clip remover, disconnect the 6 engine wire harness clamps.
d. Remove the nut, and disconnect the engine wire from the fusible link block assembly.
e. Remove the bolt, and disconnect the engine wire harness ground side.
f. Remove the 3 bolts and 3 engine wire harness clamp brackets.
g. Remove the 4 nuts, and disconnect the engine wire harness.
16. REMOVE INJECTOR DRIVER
a. Disconnect the 4 injector driver connectors.
HINT: To disconnect the injector driver connectors, push the claw downward and move the lock lever to release the lock.
b. Disconnect the 2 clamps from the injector driver.
c. Remove the 2 bolts, 2 nuts and injector driver from the intake manifold.
17. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Slide the 4 clamps, and disconnect the heater water inlet hose, heater water outlet hose, water inlet hose, and No. 3 water by-pass hose from the water by-pass pipe.
b. Remove the 2 bolts and water by-pass pipe.
18. REMOVE VACUUM SWITCHING VALVE ASSEMBLY
a. Disconnect the fuel vapor feed hose and No. 2 fuel vapor feed hose.
b. Remove the bolt and vacuum switching valve.
19. REMOVE INTAKE MANIFOLD
a. Disconnect the No.1 ventilation hose from intake manifold.
b. Remove the 8 bolts, 2 nuts and intake manifold.
c. Remove the 2 gaskets from the intake manifold.
INSTALLATION
1. INSTALL INTAKE MANIFOLD
a. Install 2 new gaskets to the intake manifold.
b. Temporarily install the intake manifold with the 2 nuts and 8 bolts. Then tighten the 2 nuts and 8 bolts uniformly in the order given in the illustration.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
c. Connect the No. 1 ventilation hose to the intake manifold.
NOTE: Face the claws of the clips as given in the illustration.
2. INSTALL VACUUM SWITCHING VALVE ASSEMBLY
a. Install the vacuum switching valve with the bolt.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
b. Connect the fuel vapor feed hose to the intake manifold.
c. Connect the No. 2 fuel vapor feed hose to the vacuum switching valve.
3. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
a. Install the water by-pass pipe to the intake manifold with the 2 bolts.
b. Connect the heater water inlet hose, heater water outlet hose, water inlet hose, and No. 3 water bypass hose to the water by-pass pipe with the 4 clamps.
NOTE: Face the No. 3 water by-pass hose clip as given in the illustration.
4. INSTALL INJECTOR DRIVER
a. Install the injector driver to the intake manifold by installing the 2 bolts and 2 nuts in the order shown in the illustration.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
b. Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as given in the illustration to lock the connectors.
c. Connect the 2 clamps to the injector driver.
5. CONNECT ENGINE WIRE
a. Connect the engine wire harness connector.
HINT: To connect the injector driver connectors, move the lock lever to lock the connector.
b. Connect the +B terminal of the generator assembly with the nut.
Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
c. Connect the 6 engine wire harness clamps.
d. Connect the engine wire to the fusible link block assembly with the nut.
Torque: 13 N.m (127 kgf.cm, 10 ft.lbf)
e. Connect the engine wire harness ground side with the bolt.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
f. Install the 3 engine wire harness clamp brackets with the 3 bolts.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
g. Connect the engine wire harness with the 4 nuts.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
6. INSTALL AIR CLEANER ASSEMBLY LH
a. Install the air cleaner case with the 2 nuts and clip.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
b. Install the air cleaner element to the air cleaner case.
c. Install the air cleaner cap with the 2 clamps.
d. Connect the MAF meter connector.
7. INSTALL AIR CLEANER ASSEMBLY RH
a. Install the air cleaner case with the 2 nuts and clip.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
b. Install the air cleaner element to the air cleaner case.
c. Install the air cleaner cap with the 2 clamps.
d. Connect the MAF meter connector.
8. INSTALL THROTTLE BODY
9. INSTALL INTAKE AIR CONNECTOR PIPE
10. INSTALL NO. 1 AIR CLEANER INLET
11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
12. ADD ENGINE COOLANT
13. INSPECT FOR ENGINE COOLANT LEAK
14. INSTALL ENGINE ROOM SIDE COVER RH
15. INSTALL AIR CLEANER INLET COVER
16. INSTALL V-BANK COVER SUB-ASSEMBLY
17. INSTALL NO. 2 ENGINE UNDER COVER
18. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER
19. INSTALL NO. 1 ENGINE UNDER COVER
20. INSTALL COWL TOP VENTILATOR LOUVER RH
21. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.