Repair Procedures

REPLACEMENT

1. Drain the engine coolant.

CAUTION:
Drain the engine coolant before removing intake manifold, or coolant flow into intake port from vent hole of cylinder head.
In that case you may have some problem in combustion chamber.

2. Remove the engine cover.




3. Remove the engine room resonator(A).




4. After disconnecting the MAF sensor connector(A) and the breather hose(B), remove the air cleaner assembly(C).




5. Disconnect the other breather hose(A), the Purge Control Solenoid Valve(PCSV) hose, the Positive Crankcase Ventilation (PCV) hose(C) and the Electronic Throttle Control(ETC) cooling hoses(D) and connector(E).








6. Remove the wiring over the surge tank.
(1) Disconnect the injection harness connector(A).
(2) Disconnect the camshaft position sensor(CMP) harness connector(B).
(3) Disconnect the ground line(C).
(4) Disconnect the ignition coil harness connector(D).
(5) Disconnect the condenser connector(E).
(6) Disconnect the variable induction system(VIS) solenoid valve connector(G).
(7) Disconnect the oil control valve(OCV) harness connector(F).
(8) Disconnect the injector wiring(H) and ignition coil wiring(I).








7. Disconnect the fuel hose tube(A).




8. Remove heater hose(A) and disconnect the brake vacuum hose(B).




9. Disconnect the surge tank stay.
10. Remove the surge tank.
11. Disconnect the injector connectors.
12. Disconnect the water hose on intake manifold from the nipple on the chain cover.
13. Remove the delivery pipe and intake manifold as an assembly.

NOTE:
Except such cases as defects of injectors or pipe, do not disassemble a delivery pipe from an intake manifold because it is one of the fuel system parts, or you may have some problem in fuel system.

14. Install intake manifold and new gasket on the cylinder head.

Tightening torque
1st : 3.9 - 5.9Nm (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
2nd
Bolt : 26.5 - 31.4Nm (2.7 - 3.2kgf.m, 19.5 - 23.1lb-ft)
Nut : 18.6 - 23.5Nm (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)
3rd : Repeat 2nd step twice or move.


NOTE:
Be careful of the installation direction.
a - h : 1st step order
1 - 8 : 2nd step order




15. Connect the water hose on intake manifold to the nipple on the chain cover.
16. Install delivery pipe. .
17. Install the surge tank and new gasket on the intake manifold.

Tightening torque
Long bolt : 9.80 - 11.76Nm (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
Short bolt, nut : 18.6 - 23.5Nm (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)


18. Connect heater hose(A) and the brake vacuum hose(B).




19. Connect the fuel hose tube(A).




20. Connect the wiring over the surge tank.
(1) Connect the injection harness connector(A)
(2) Connect the camshaft position sensor(CMP) harness connector(B).
(3) Connect the ground lines(C).
(4) Connect the ignition coil harness connector(D).
(5) Connect the condenser connector(E).
(6) Connect the variable induction system(VIS) solenoid valve connector(G).
(7) Connect the oil control valve(OCV) harness connector(F).




21. Connect the other breather hose(A), the Positive Crankcase Ventilation (PCV) hose(C) and the Electronic Throttle Control(ETC) cooling hoses(D), ETC connector(E).








22. After connecting the MAF sensor connector(A) and the breather hose(B), install the air cleaner assembly(C).




23. Install the engine room resonator(A).





Tightening torque
9.80 - 11.76Nm (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)


24. Remove the engine cover(A).





Tightening torque
9.80 - 11.76Nm (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)


25. Fill with engine coolant.