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Removal and Installation
 
 
REMOVAL
warningTo avoid the danger of being scalded, do not drain the coolant when the engine is hot.
noteWhen removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.
 
 
1. Disconnect battery negative terminal.
2. Remove the air cleaner case assembly and air duct. Refer to Removal and Installation.
3. Partially drain engine coolant. Refer to Draining.
4. Disconnect harness connector from the electric throttle control actuator.
5. Disconnect water hoses from the electric throttle control actuator.
noteWhen removing only intake manifold, position electric throttle control actuator aside without disconnecting the water hose.
6. Loosen bolts in reverse order as shown, then remove electric throttle control actuator and electric throttle actuator gasket.
cautionHandle carefully to avoid any damage.
7. Disconnect the brake booster vacuum hose and brake booster vacuum tube from the intake manifold.
8. Remove the EGR outlet tube .
9. Remove CVT fluid charging pipe. Refer to Exploded View.Exploded View
10. Disconnect the PCV hose from the intake manifold assembly.
11. Disconnect the EVAP canister purge volume control solenoid valve hose 1 from the intake manifold assembly.
12. Disconnect harness connectors from the intake manifold runner control valve motor, intake manifold runner control valve position sensor, intake manifold tuning valve motor and manifold absolute pressure (MAP) sensor.
13. Release harness retainers from intake manifold.
14. Loosen nuts and bolts in reverse of the sequence shown and remove the intake manifold.
caution
  • Do not reuse intake manifold gasket.
  • Cover engine openings to prevent entry of foreign materials.
note
  • Disregard No. 6 when loosening.
  • When removing intake manifold, make sure to remove harness retainers from bottom of intake manifold.
15. Remove intake port insulator.
cautionDo not reuse intake port insulator gasket.
16. Remove the intake manifold stud if necessary.
 
 
INSTALLATION
Installation is in the reverse order of removal.
  • Add engine coolant if necessary. Refer to Refilling.
  • Perform the “Throttle Valve Closed Position Learning” when harness connector of electric throttle control actuator is disconnected. Refer to Work Procedure.
  • Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electric throttle control actuator is replaced. Refer to Work Procedure (Idle Air Volume Learning) and Work Procedure (Throttle Valve Closed Position Learning).
 
 
Intake Manifold
1. Install the intake manifold stud if removed.
2. Install intake port insulator.
cautionDo not reuse intake port insulator gasket.
3. Securely install intake manifold gasket to the mounting groove.
cautionDo not reuse intake manifold gasket.
4. Install and tighten intake manifold nuts and bolts using the following procedure:
cautionDo not reuse intake manifold gasket.
(1) Hand tighten bolts (4 and 5).
(2) Tighten intake manifold nuts and bolts to the specified torque in the sequence shown.
1, 4, 5, 6: 25.0 N·m (2.6 kg-m, 18 ft-lb)
2, 3: 25.0 N·m (2.6 kg-m, 18 ft-lb)
7: 25.0 N·m (2.6 kg-m, 18 ft-lb)
5. Connect harness retainers before installing intake manifold.
6. Installation is in the reverse order of removal.
 
 
Electric Throttle Control Actuator
1. Install a new gasket on the electric throttle control actuator.
cautionDo not reuse electric throttle control actuator gasket.
2. Tighten the bolts of electric throttle control actuator in numerical order as shown.
: 10.0 N·m (1.0 kg-m, 89 in-lb)