Removing
1. Remove the cover (1) from the engine.
2. Upper intake manifold
3. Rubber bushing
2. Disconnect the duct (inlet) and air duct (between air cleaner housing and throttle motor). See section «Air cleaner and air duct».
3. Move the tank. See chapter Lubrication system and engine cooling system.
4. Disconnect the water hoses from the throttle motor, install plugs to prevent coolant leakage.
Attention:
- Perform this operation when the engine is cold.
- Keep engine coolant away from drive belts.
5. Remove the dipstick.
Caution: Plug the oil dipstick guide hole to prevent foreign particles from entering.
6. Remove the throttle motor.
Attention:
- Handle the drive with care and avoid shock.
- Do not disassemble or make adjustments.
7. Disconnect the EVAP connector and hose from the EVAP charcoal filter purge solenoid valve.
Caution: Handle the solenoid valve with care and avoid impact.
8. Disconnect the brake booster vacuum hose from the top of the intake manifold.
9. Remove the front (1) and back (2) upper intake manifold mounts.
10. Remove the upper part of the intake manifold.
Loosen the mounting bolts in the reverse order shown in the figure.
11. If necessary, remove the EVAP carbon filter purge solenoid valve from the top of the intake manifold.
Caution: Handle the solenoid valve with care and avoid impact.
12. If necessary, remove the support of the upper part of the intake manifold (central) from the cylinder head.
Note: When installing the upper part of the intake manifold, the center support serves as a guide.
Installation
Installation is carried out in the reverse order of removal, taking into account the following:
Upper intake manifold
1. Place a gasket on top of the intake manifold.
Align the ledge (A) on the grooved gasket at the top of the intake manifold.
2. Reinstall the upper part of the intake manifold.
Caution: Make sure that the dipstick guide has not become detached from the mounting clip on the intake manifold due to grabbing the top of the intake manifold.
3. Tighten the bolts in the order indicated by the numbers in the figure.
4. Install the upper intake manifold supports.
Throttle actuator
Tighten the bolts evenly in a criss-cross pattern in several passes. If the connector is disconnected from the throttle motor, run «Throttle closed learning». See chapter Engine management system.
When replacing the throttle actuator, carry out «Learning to supply air at speed x.x.» And «Throttle closed learning». See chapter Engine management system.