Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Disconnect the negative battery terminal.
2. Remove the vacuum booster.
BRAKE SYSTEM, Rear brake drum, Vacuum booster - for vehicles with KV6 engine.
3. Place a rag near the fuel supply hose to prevent spilled fuel from spreading.
CAUTION: Fuel leakage is inevitable during this operation. Take safety measures to prevent fire or explosion.
4. Slide back the rubber bushing on the fuel line connector, release the connector and disconnect the supply line from the fuel rail.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
5. Loosen the clamp and disconnect the hose from the canister purge valve.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
6. Disconnect the connector from the purge solenoid valve.
7. Except for North American models: Disconnect the thin vacuum hose from the canister purge valve.
8. Except for North American models: Press the shoulders and remove the vacuum hose from the idle air control valve housing.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
9. Except for North American models: Disconnect the connector from the idle air control valve.
10. Except for North American models: Disconnect the connector from the throttle position sensor.
11. Except for North American models: Press the retainer shoulders and disconnect the vacuum/purge hose from the purge valve and from the left valve cover. Loosen the clamp securing the hose to the tee and remove the hose.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
12. Except for North American models: Press the retainer shoulders and disconnect the vacuum/purge hose from the throttle body, right and left valve covers and remove the hose.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
13. Except for North American models: Release the throttle control cable from the clips on the wiring harness brackets.
14. Except for North American models: Disconnect the cable housing from the bracket and disconnect the cable from the sector on the throttle body.
15. Except for North American models: Disconnect the vacuum hose from the cruise control actuator.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
16. North American Models: Press the retainer shoulders and disconnect the vacuum/purge hose from the right and left valve covers and remove the hose.
17. North American models: Disconnect the clamp securing the vacuum/ventilation hose to the air intake hose and disconnect the vacuum/ventilation hose from the air hose. Discard the clamp.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
18. North American models: Press the shoulders and remove the vacuum/vent hose from the left valve cover, from the right valve cover connecting hose and from the intake manifold. Remove the connecting hose.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
19. North American models: Disconnect the connector from the intake air temperature (IAT) and mass air flow (MAF) sensors.
20. North American models: Disconnect the connector from the throttle body.
21. North American models: Remove the clamp securing the air intake hose to the throttle body, remove the air intake hose with the air flow sensor. Discard the clamp.
22. North American Models: Release the wiring harness and fuel feed pipe from the clamps on the intake manifold.
23. Disconnect the connector from the intake manifold tuning system electric motors.
24. Unscrew the two screws securing the engine harness brackets to the intake manifold and move the harness to the side.
25. Unscrew the 2 bolts securing the rear receiver brackets to the right valve cover.
26. Unscrew the 4 bolts securing the intake receiver to the left intake manifold.
27. Release the 3 latches and disconnect the 3 connectors from the ignition coils of the right bank of cylinders.
28. Release the receiver and lift it above the intake manifolds.
29. Release the right-hand row ignition coil harnesses from the two clamps securing them to the intake manifold brackets.
30. Remove the intake receiver.
31. Remove and discard the seals from the intake manifold and the O-rings from the right intake manifold.
Installation
1. Clean the sealing surfaces of the intake manifold and intake receiver.
2. Install new sealing rings on the right intake manifold and new seals on the intake receiver.
3. Install the intake manifold, secure the right row ignition coil harness to the intake manifold brackets.
4. Align the intake manifold with the intake manifolds, install the bolts and tighten them to 18 Nm.
5. Install the intake manifold mounting bracket to the right valve cover, screw in the bolts and tighten them to 10 Nm.
6. Connect the connectors to the ignition coils and secure the connectors with clamps.
7. Install the engine harness brackets onto the intake manifold, screw in and tighten the screws.
8. Connect the connector to the intake manifold tuning system motor.
9. North American models: Install the wiring harness and fuel line. Secure the harness and line to the intake manifold with a clamp.
10. North American models: Using a new clamp, install the air intake hose to the throttle body and secure it.
11. North American models: Attach the connector to the throttle body.
12. North American models: Connect the intake air temperature (IAT) and mass air flow (MAF) sensor connectors.
13. North American models: Connect the vacuum hose/vent hose to the left valve cover, to the right valve cover connector tube and to the intake manifold.
14. North American models: Using a new clamp, attach the vacuum/ventilation hose to the air intake hose and secure it in place.
15. North American models: Attach the vacuum/vent hose to the right and left valve covers. Secure the hose with the clamp.
16. Except for North American models: Connect the vacuum hose to the cruise control actuator.
17. Except for North American models: Connect the vacuum/vent hose to the throttle body and to the right and left valve covers.
18. Except for North American models: Connect the vacuum/vent hose to the canister purge valve and to the left valve cover. Connect the hose to the tee and secure with a new tee.
19. Except for North American models: Connect the connector to the throttle position sensor.
20. Except for North American models: Connect the connector to the idle air control valve.
21. Except for North American models: Connect the vacuum hose to the idle air control valve.
22. Except for North American models: Connect a thin vacuum hose to the canister purge valve.
23. Connect the connector to the purge solenoid valve of the adsorber.
24. Connect the purge hose to the canister purge valve.
25. Connect the fuel line to the fuel rail, slide the rubber bushing onto the connection.
26. Except for North American models: Secure the throttle control cable to the throttle lever and the cable housing to the bracket.
27. Except for North American models: Secure the throttle control cable to the clips on the wiring harness brackets.
28. Except for North American models: Adjust the throttle control cable.
FUEL SUPPLY SYSTEM OF GASOLINE ENGINE, ADJUSTMENTS, Throttle control cable - checking and adjustment: KV6 engine.
29. Install the vacuum booster.
BRAKE SYSTEM, Rear brake drum, Vacuum booster - for vehicles with KV6 engine.
30. Connect the negative terminal to the battery.
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