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INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L8, LF, L3]

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Warning

•  When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the intake-air system.

•  Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See BEFORE SERVICE PRECAUTION [L8, LF, L3].)

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [L8, LF, L3, L3 Turbo].)

2.  Remove in the order indicated in the table.

3.  Install in the reverse order of removal.

4.  Complete the “AFTER REPAIR PROCEDURE”. (See AFTER SERVICE PRECAUTION [L8, LF, L3].)

5.  Add the engine coolant to the cooling system filler neck and the coolant reserve tank to replace that during servicing.

6.  Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [L8, LF, L3, L3 Turbo].)

7.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [L8, LF, L3, L3 Turbo].)

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1	Air cleaner cover
2	Air cleaner element
3	Air cleaner case (See Air Cleaner Case Installation Note.)
4	Resonance chamber (See Resonance Chamber Removal Note.)
5	VAD solenoid valve (L3)
6	VAD shutter valve (L3)
7	Mass air flow sensor
8	Vacuum hose (purge solenoid valve) (See Vacuum Hose (Purge Solenoid Valve) Installation Note.)
9	Purge solenoid valve
10	Air hose
11	Throttle body (See Throttle Body Removal Note.) (See Throttle Body Installation Note.)
12	Variable tumble solenoid valve
13	Variable intake air solenoid valve (LF, L3)
14	Fuel injector connector
15	Plastic fuel hose (See FUEL INJECTOR REMOVAL/INSTALLATION [L8, LF, L3].) (See FUEL INJECTOR REMOVAL/INSTALLATION [L8, LF, L3].)
16	Fuel distributor
17	Intake manifold
18	VAD check valve (L3)

Resonance Chamber Removal Note

1.  Remove the front mudguard (LH) before removing the resonance chamber.

Throttle Body Removal Note

Warning

•  Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.

•  When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

Caution

•  Do not plug the water hose with a sharp-edged object. Otherwise, the hose could be damaged.

1.  Wrap a clean cloth around the cooling system cap and release the pressure by loosening the cap slowly.

2.  Remove the water hose from the throttle body and plug the water hose quickly.

3.  Remove the throttle body.

Throttle Body Installation Note

1.  Install the throttle body.

2.  Remove the plug from the water hose and install the water hose to the throttle body quickly.

Vacuum Hose (Purge Solenoid Valve) Installation Note

1.  Fit the vacuum hose (purge solenoid valve) onto the respective fittings, and install clamps as shown.

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Air Cleaner Case Installation Note

Caution

•  Before assembling the air cleaner, verify that the rubber mounts have not fallen off from the air cleaner bracket (3 locations).

•  Always install the air cleaner case using the following procedure.

Note

•  When inserting the rubber mounts into the air cleaner case, soapy water can be applied.

1.  Verify that the rubber mounts are set in the air cleaner bracket (3 locations).

2.  Install the projections on the frame side (2 locations).

3.  Verify that the projections on the frame side are installed securely.

4.  Install the projection on the engine side (remaining location).

5.  Verify that the projection on the engine side installed securely.