Special tool
Fuel system spring release tool 310-044 |
Removing
NOTE: Removal of the intake manifold on early models requires partial removal of the fuel rail and removal of the purge valve and support bracket. Also, after removal, it is required to remove some excess material from the intake manifold; see steps 1 and 2 of the installation procedure.
1. Disconnect a wire of weight from the storage battery. For more information, refer to Specification
2. Secure the hood in the service position. Release the hood pillars.
3. Remove the engine cover. For more information refer to Engine Cover - 4.0L (12.30.50)
4. Remove the air intake resonator. For more information refer to Air Intake Resonator (19.70.03)
5. Disconnect the throttle body electrical connector.
6. Disconnect the intake manifold coolant hose.
- To minimize coolant loss, pinch the appropriate hose.
- Release the clamp.
7. Disconnect the throttle body coolant hose.
- Pinch the hose to minimize coolant loss.
- Release the clamp.
8.
CAUTION: Before disconnecting or dismantling parts, make sure that there is no contamination around the contact surfaces and connections. Close all open connections to avoid contamination of the system.
Disconnect the crankcase ventilation hose.
9. Disconnect the right crankcase ventilation hose.
10. Disconnect the EGR valve electrical connector.
11. Disconnect the EGR valve supply line.
- Loosen the union nut on the EGR valve supply line on the exhaust manifold.
- Disconnect the union nut securing the EGR line to the valve.
12. Disconnect the intake manifold vacuum tube assembly.
13. Disconnect the intake manifold trim valve electrical connector.
14. Attach the purge line to the intake manifold.
- Turn out a bolt of fastening of a clip.
- Select a spacer.
15. Release the coil harness.
- Release 6 clips.
- Loosen the 2 coil harness ground nuts.
16. Disconnect 6 electric sockets of coils.
17.
NOTE: Mark the mounting positions of the fasteners.
Remove the 2 rear ignition coils.
- Disconnect the spark plug wires from the coils.
- Remove 2 bolts and 2 studs.
- Discard retainer o-rings to facilitate subsequent installation.
18. Disconnect high voltage wires from ignition coils. Move the wires aside.
19. Move aside the engine wiring harness to provide access.
20. Turn out 8 bolts of an inlet collector.
21.
NOTE: Clamp type may vary depending on steering position. Release the intake manifold wiring harness clamp.
22.
WARNING: The vehicle must be kept in an enclosed area with good ventilation. Signs must be posted around the vehicle "No smoking! Pairs of gasoline!"
CAUTION: Some fuel will inevitably spill during this operation. Take all necessary measures to prevent fire and explosion.
WARNING: Wait at least 30 seconds after stopping the engine before attempting any repair to the high pressure fuel injection system. Failure to follow this instruction may result in injury.
WARNING: If fuel gets in your eyes, rinse them with cold water or eyewash solution and seek immediate medical attention.
Disconnect the fuel line using the special tool.
- Remove the safety clip.
- Early models only: Remove the 4 bolts and release the fuel rail and fuel injectors.
- Early models only: Disconnect the left and right cylinder heads and the rear fuel injector electrical connectors.
- Early Models Only: Remove the bolt and release the cylinder head cover fuel line clip.
- Early models only: Attach the purge valve to the wire harness with a wire tie.
23.
NOTICE: Early models only: The purge valve and support bracket are bolted to the rear of the intake manifold and come into contact with the fuel manifold bypass line. Attempting to remove the intake manifold with force will result in damage. In this case, to access the purge valve mounting bolt, disconnect the inner wall and base of the battery tray on the left side.
CAUTION: Be careful not to damage the purge valve assembly when removing the intake manifold.
NOTE: Due to difficulty of access, it may be necessary to break the clamps of the engine and transmission wiring harnesses. Be careful not to damage the wiring harnesses.
Loosen and then remove the intake manifold.
- Discard the gaskets.
- Insert plugs into open holes.
24.
NOTE: Do not proceed with further disassembly if the part is being removed only for access.
Remove the throttle body.
- Remove 4 bolts.
- Remove the throttle body gasket and discard it. Disconnect the coolant hose.
25. Disconnect the EGR valve vacuum hose. Disconnect and remove the vacuum hose from the intake manifold.
26. Remove the EGR valve.
- Turn out 2 bolts.
- Take and discard the gasket.
27. Remove the remaining ignition coils.
- Disconnect the spark plug wires from the coils.
- Turn out bolts and hairpins. Remove seals and discard.
29. Remove the intake manifold adjusting valve.
- Turn out 2 bolts.
- Discard the O-ring.
Installation
1.
CAUTION: After removing the material, check that there are no sharp edges.
Early Models Only: Remove the center cast lug.
2. Early Models Only: Remove excess material from outside edges of intake manifold flange faces 6; align them with a file so that they are within 2mm of the edge of the gasket.
3. Early models only: Install the fuel rail and fuel injectors.
- Clean the contact surfaces of the parts.
- Tighten the bolts (tightening torque 25 Nm).
- Connect the fuel injector electrical connectors.
- Tighten the M6 bolt (tightening torque 10 Nm).
- Clean the contact surfaces of the parts.
- Install a new sealing ring.
- Tighten the bolts with a torque of 10 Nm.
6.
NOTE: Mark the mounting positions of the fasteners.
Install 4 ignition coils.
- Tighten the bolts (tightening torque 6 Nm).
- Tighten the studs (tightening torque 6 Nm).
- Connect high voltage electrical connectors.
- Clean the contact surfaces of the parts.
- Install a new gasket.
- Tighten the bolts (tightening torque 25 Nm).
9. Connect the EGR vacuum hose to the intake manifold.
- Clean the contact surfaces of the parts.
- Connect the vacuum hose to the EGR valve.
- Clean the contact surfaces of the parts.
- Install a new gasket.
- Tighten 4 bolts (tightening torque 10 Nm).
- Fasten the clamp.
- Remove the hose clamp.
13.
CAUTION: Take precautions before tightening intake manifold bolts. Make sure that the wiring harnesses, vacuum and purge valve lines are not pinched.
NOTE: For ease of installation: Before installing the intake manifold, install a Torx wrench with extension on the left-hand row intake manifold Torx bolt. Secure it with tape.
NOTE: Ignition coils are not shown for clarity.
Install the intake manifold.
- Clean the contact surfaces of the parts.
- Install gaskets.
- Tighten the bolts evenly and progressively in the sequence shown (tightening torque 10 Nm).
14. Install the remaining ignition coils.
- Tighten the bolts (tightening torque 6 Nm).
- Tighten the studs (tightening torque 6 Nm).
- Connect high voltage electrical connectors.
16. Connect the fuel line to the fuel rail.
- Clean the contact surfaces of the parts.
- Install the clamp.
- Connect the coil ground wires.
- Tighten nuts (tightening torque 6 Nm).
- Install and secure clamps.
19. Connect the vacuum tube to the intake manifold.
20. Attach the purge line to the intake manifold.
- Install the spacer.
- Screw in the bolt.
- tighten bolt (tightening torque 6 Nm).
22. Connect the intake manifold coolant hose.
- Fasten the clamp.
- Remove the hose clamp.
24. Install the engine cover. For more information refer to Engine Cover - 4.0L (12.30.50)
25. Attach the hood pillars.
26. Connect a wire of weight to the storage battery. For more information, refer to Specification
27. Check the coolant level and top up if necessary.
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