Contents: Removal ⬇ Installation ⬇
Removal
Disconnect the negative battery terminal.
Disconnect the air flow meter wire. Remove the sealing ring where required.
Loosen the air duct clamp screw on the right side of the air flow meter.
Using a socket wrench, loosen the four bolts securing the air box to the throttle body.
Lift the air box off the throttle body and disconnect the hose from the base of the air box, then remove the air box/air flow meter assembly.
Disconnect the electrical connector from the throttle position sensor.
Remove the end of the cable from the throttle lever, then remove the rubber grommet on the end of the cable from the bracket located on the intake manifold and move the throttle cable to the side.
Disconnect the two breather hoses from the back of the camshaft cover. Disconnect the larger hose from the main throttle body and remove it.
Place a rag under one of the fuel hose fittings on the fuel rail to catch any escaping fuel while disconnecting the fitting.
Slowly loosen the fuel hose fitting, gradually reducing the pressure in the fuel system, then disconnect the hose from the distributor. Fuel leakage may occur, so take fire safety measures. Clamp the fuel hose to prevent dirt from entering and fuel leakage.
Repeat the operations for the remaining fuel hose connections to the fuel distributor.
Disconnect the vacuum lines from the front of the traction control system (TCS) throttle body.
Disconnect the coolant hoses from the throttle body of the RTU, marking their location for subsequent installation. Coolant leakage is possible, so clamp the hose to reduce coolant loss.
Disconnect the harness housing from the fuel injectors and set it aside, being careful not to put tension on the wires. Lift the housing and squeeze the connector clamps to release the housing from the injectors.
Loosen the nut and disconnect the brake booster vacuum hose from the left side of the intake manifold.
Loosen the nut and remove the fuel hose bracket from the left side of the throttle body.
Remove the nuts and disconnect the ground wires from the fuel distributor studs at both ends.
Loosen the bolt and remove the cable/hose assembly mounting bracket from the left side of the intake manifold.
Remove the idle air control valve as described in one of the sections earlier.
Unscrew the upper nut and generator mounting bolt.
Make sure all relevant hoses, tubes and wires are disconnected.
After unscrewing the nuts, remove the intake manifold and ancillary components.
Installation
The order of execution of works as specified above in the subsection "Installing the intake manifold", however, make sure that the RTU system throttle body cooling hoses are located and connected as before removal.
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