RM3660EC _51 Engine / Hybrid System _080790 8ZR-FXE INTAKE / EXHAUST _0392072 INTAKE MANIFOLD A

8ZR-FXE INTAKE / EXHAUST INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during intake manifold removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
· Replacement of throttle body assembly · Cleaning the deposits from the throttle body assembly	Inspection after repair	· Poor idle, etc. · Engine start function, etc.	(202304,999999,_51,_080778,_0393982,RM100000002BDLI,)

PROCEDURE

Hide Display 22210 1.REMOVE THROTTLE BODY ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE CONTROL)>THROTTLE BODY>REMOVAL202304,999999,_51,_080778,_0392133,RM10000000295TV,

Hide Display 53289A 2.REMOVE RADIATOR SUPPORT OPENING COVER

for TFTM Made:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for TFTM Made)>REMOVAL202304,202307,_59,_080736,_0392548,RM100000002AMO3_01_0035,202307,999999,_59,_080736,_0392548,RM100000002CH8T_01_0035,

for GTMC Made:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for GTMC Made)>REMOVAL202304,202307,_59,_080736,_0392547,RM100000002AXCM_01_0036,202307,999999,_59,_080736,_0392547,RM100000002CHFA_01_0036,

Hide Display 17752 3.REMOVE INLET NO. 2 AIR CLEANER

Loosen the hose clamp.

Remove the bolts, clip and inlet No. 2 air cleaner from the inlet No. 1 air cleaner and upper radiator support sub-assembly.

Hide Display 17801 4.REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

Hide Display 17701 5.REMOVE AIR CLEANER CASE SUB-ASSEMBLY

Remove the 2 bolts and air cleaner case sub-assembly from the air cleaner bracket.

Hide Display 17771A 6.REMOVE AIR CLEANER BRACKET

Remove the 2 bolts and disengage the 2 wire harness clamp and hose clamp to remove the air cleaner bracket from the cylinder block sub-assembly and air conditioning wire, No.1 radiator hose.

Hide Display 17751 7.REMOVE INLET NO. 1 AIR CLEANER

Remove the 2 bolts and inlet No. 1 air cleaner from the intake manifold.

Hide Display 25610 8.REMOVE EGR PIPE ASSEMBLY

Remove the 4 bolts and EGR pipe assembly from the intake manifold and EGR valve assembly.

Remove the inlet EGR gasket from the intake manifold.

Remove the EGR pipe gasket from the EGR valve assembly.

Hide Display 89421 9.REMOVE E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)

Disconnect the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) connector.

Disconnect the vacuum hose from the intake manifold.

Remove the bolt and E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) from the intake manifold.

Hide Display 12261 10.DISCONNECT VENTILATION HOSE

Slide the clip and disconnect the ventilation hose from the intake manifold.

Hide Display 82121 11.DISCONNECT ENGINE WIRE

Disengage the 2 clamps.

Disconnect the engine water pump assembly connector.

Remove the bolt and disconnect the wire harness bracket.

Disconnect the 4 fuel injector assembly connectors and purge valve (purge VSV) connector.

Remove the bolt and disengage the clamp to disconnect the engine wire.

Hide Display 12.DISCONNECT ENGINE COVER BRACKET

Remove the bolt and disconnect the engine cover bracket from the intake manifold.

Hide Display 16296 13.DISCONNECT NO. 8 WATER BY-PASS HOSE

Disengage the 2 hose clamps.

Slide the clip and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe.

Hide Display 23827A 14.DISCONNECT NO. 2 FUEL VAPOR FEED HOSE

Disconnect the No. 2 fuel vapor feed hose.

Disengage the 2 hose clamps and disconnect the No. 2 fuel vapor feed hose from the intake manifold.

Hide Display 15.DISCONNECT WATER BY-PASS HOSE

0.427,0.365 0.583,0.365 0.583,0.365 0.688,0.667 true 1.969,0.208 1.833,0.208 1.833,0.208 1.698,0.51 true 1.979,0.115 2.198,0.302 0.219,0.188 10 true *1 0.24,0.281 0.448,0.469 0.208,0.188 10 true *2

*1	Water By-Pass Hose
*2	No. 2 Water By-pass Hose

Disengage the 2 hose clamps and disconnect the water by-pass hose from the intake manifold.

Disengage the 2 hose clamps and disconnect the No. 2 water by-pass hose from the intake manifold.

Hide Display 17111 16.REMOVE INTAKE MANIFOLD

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	Bolt
	Nut

Remove the 3 bolts and 2 nuts and intake manifold from the cylinder head sub-assembly.

Hide Display 17177 17.REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Remove the No. 1 intake manifold to head gasket from the intake manifold.

Hide Display 18.REMOVE STUD BOLT (w/ Stud Bolt)

HINT:: If a stud bolt is deformed or the threads are damaged, replace it.

Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.