Removal

REMOVAL PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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2. DISCHARGE FUEL SYSTEM PRESSURE

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3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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4. REMOVE NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (w/ Off Road Package)

5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

6. DRAIN ENGINE COOLANT

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7. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Raise the front of the V-bank cover to disengage the 2 pins. Text in Illustration *a Pin *b Guide

(b) Disengage the 2 guides to remove the V-bank cover sub-assembly.

8. REMOVE NO. 1 V-BANK COVER BRACKET

(a) Remove the 2 bolts and No. 1 V-bank cover bracket from the intake air surge tank assembly.

9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH NO. 1 AIR CLEANER HOSE

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10. REMOVE NO. 2 SURGE TANK STAY

(a) Remove the 2 bolts and No. 2 surge tank stay from the cylinder head LH and intake air surge tank assembly.

11. REMOVE NO. 1 SURGE TANK STAY

(a) Remove the 2 bolts and No. 1 surge tank stay from the cylinder head LH and intake air surge tank assembly.

12. REMOVE THROTTLE BODY BRACKET

(a) Remove the 2 bolts and throttle body bracket from the timing chain cover assembly and intake air surge tank assembly.

13. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

(a) Disconnect the throttle body with motor connector from the throttle body with motor assembly.

(b) Slide the 2 clips and disconnect the No. 4 water by-pass hose and No. 5 water by-pass hose from the throttle body with motor assembly.

(c) Slide the clip and disconnect the fuel vapor feed hose from the purge VSV.

(d) Disengage the clamp to separate the fuel vapor feed hose from the intake air surge tank assembly.

(e) Disconnect the purge VSV connector from the purge VSV.

(f) Disengage the 2 clamps to separate the wire harness from the intake air surge tank assembly.

(g) Disengage the clamp to disconnect the No. 1 fuel pipe sub-assembly and No. 2 fuel pipe sub-assembly from the intake air surge tank assembly.

(h) Disengage the clamp to disconnect the heater hose from the intake air surge tank assembly.

(i) Disconnect the intake air control valve actuator connector from the intake air control valve actuator.

(j) Slide the clip and disconnect the PCV hose from the intake air surge tank assembly.

(k) Remove the 2 nuts, 5 bolts and intake air surge tank assembly from the intake manifold.

Text in Illustration

	Bolt
	Nut

(l) Remove the surge tank to intake manifold gasket from the intake air surge tank assembly.

14. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

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15. DISCONNECT ENGINE WIRE

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16. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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17. REMOVE INTAKE MANIFOLD

(a) Remove the 4 nuts, 4 bolts and intake manifold from the cylinder head sub-assembly and cylinder head LH.

Text in Illustration

	Bolt
	Nut

(b) Remove the 2 No. 1 intake manifold to head gaskets from the cylinder head sub-assembly and cylinder head LH.