Repair Procedures

Removal

CAUTION:
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:
- Mark all wiring and hoses to avoid misconnection.

1. Disconnect the battery negative cable.
2. Loosen the drain plug and drain the engine coolant.
3. Remove the air duct (A).
4. Remove the AFS connector (B) and air cleaner assembly (C).




5. Remove the PCSV connector (A), PCSV hose (B) and throttle body coolant hoses (C).




6. Disconnect the brake vacuum hose (A).




7. Disconnect the LH injector connectors (A).




8. Disconnect the MAP sensor connector (A), ETC connector (B), PCV hose (C) and then remove the surge tank (D).




9. Remove the surge tank gasket (A).




10. Remove the fuel hose (A).




11. Disconnect the RH injector connector (A).




12. Disconnect the water vent hose (A) and then remove the intake the manifold (B).

CAUTION:
- Be sure to drain the engine coolant before removing the intake manifold.
- If any coolant drained from the cylinder head vent hole has entered the intake port. This can potentially lead to engine trouble.





Installation

1. Install the intake the manifold (B) with a new gasket, and connect the water vent hose (A).

CAUTION:
- Be sure to drain the engine coolant before removing the intake manifold.
- If any coolant drained from the cylinder head vent hole has entered the intake port. This can potentially lead to engine trouble.

Tightening torque
Step 1: 3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
Step 2:
Nut- 18.62 - 23.52N.m (1.9 - 2.4kgf.m, 13.74 - 17.36lb-ft)
Bolt -26.5 - 31.4N.m (2.7 - 3.2kgf.m, 19.5 - 23.1lb-ft)
Step 3: Repeat 2nd step twice or more.





a - h : 1st step order
1 - 8 : 2nd step order

NOTE:
Confirm the manifold gasket identification mark (LH, RH) and be careful of the installation direction.




2. Connect the RH injector connector (A).




3. Install the fuel pipe (A) and vacuum pipe (B).




4. Install the new surge tank gasket (A).




5. Install the surge tank assembly (D), MAP sensor connector (A), ETC connector (B) and PCV hose (C).

Tightening torque :
18.6 - 23.5N.m (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)




6. Connect the LH injector connectors (A).




7. Connect the brake vacuum hose (A).




8. Connect the PCSV connector (A), PCSV hose (B) and throttle body coolant hoses (C).




9. Install the air cleaner assembly (C) and connect the AFS connector (B).
10. Install the air duct (A).

Tightening torque :
Bolt : 7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
Clamp : 2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.2 - 3.6lb-ft)




11. Connect the battery negative cable.

NOTE:
- Refill engine coolant.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.
- Clean the battery posts and cable terminals with sandpaper. Assemble and, then apply grease to prevent corrosion.