Removal and Installation
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. DRAIN ENGINE COOLANT
4. REMOVE V-BANK COVER
a. Remove the 2 nuts and cover.
5. REMOVE INTAKE AIR CONNECTOR PIPE
a. Disconnect the air hose and ventilation hose.
b. Loosen the 2 clamps. Then remove the bolt and intake air connector pipe.
6. REMOVE THROTTLE BODY ASSEMBLY
7. REMOVE NO. 1 V-BANK COVER BRACKET
a. Remove the bolt and cover bracket.
8. REMOVE NO. 2 V-BANK COVER BRACKET
a. Remove the bolt and cover bracket.
9. REMOVE NO. 3 V-BANK COVER BRACKET
a. Remove the bolt and cover bracket.
10. REMOVE NO. 4 V-BANK COVER BRACKET
a. Remove the bolt and cover bracket.
11. REMOVE PURGE VSV
a. Disconnect the purge VSV connector.
b. Disconnect the 2 hoses from the purge VSV.
c. Remove the bolt and purge VSV.
12. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
a. Using SST, disconnect the fuel pipe.
SST 09023-38401
13. REMOVE INTAKE MANIFOLD
a. Disconnect the vacuum hose of the brake booster.
b. Disconnect the air hose of the power steering.
c. Disconnect the ventilation hose.
d. Disconnect the 8 injector connectors.
e. Remove the 6 bolts, 4 nuts and intake manifold.
14. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET
INSTALLATION
1. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET
a. Install 2 new gaskets to the cylinder head as shown in the illustration.
HINT: Make sure the white paint marks are facing upward.
2. INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 6 bolts and 4 nuts.
Torque: 18 N.m(184 kgf.cm, 13 ft.lbf)
b. Connect the 8 injector connectors.
c. Disconnect the ventilation hose.
d. Connect the air hose for the power steering.
e. Connect the vacuum hose for the brake booster.
3. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY
a. Using SST, install the fuel pipe.
SST 09023-38401
Torque:
35 N.m(357 kgf.cm, 26 ft.lbf) for use without SST
28 N.m (286 kgf.cm, 21 ft.lbf) for use with SST
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
4. INSTALL PURGE VSV
a. Install the purge VSV with the bolt.
Torque: 7.5 N.m(76 kgf.cm, 66 in.lbf)
b. Connect the 2 hoses for the purge VSV.
c. Connect the purge VSV connector.
5. INSTALL NO. 4 V-BANK COVER BRACKET
a. Install the cover bracket with the 2 nuts.
Torque: 7.5 N.m(76 kgf.cm, 66 in.lbf)
6. INSTALL NO. 3 V-BANK COVER BRACKET
a. Install the cover bracket with the bolt.
Torque: 7.5 N.m(76 kgf.cm, 66 in.lbf)
7. INSTALL NO. 2 V-BANK COVER BRACKET
a. Install the cover bracket with the bolt.
Torque: 7.5 N.m(76 kgf.cm, 66 in.lbf)
8. INSTALL NO. 1 V-BANK COVER BRACKET
a. Install the cover bracket with the bolt.
Torque: 7.5 N.m(76 kgf.cm, 66 in.lbf)
9. INSTALL THROTTLE BODY ASSEMBLY
10. INSTALL INTAKE AIR CONNECTOR PIPE
a. Install the intake air connector pipe with the bolt and hose clamp.
Torque:
4.0 N.m(41 kgf.cm, 35 in.lbf) for hose clamp
5.0 N.m (51 kgf.cm, 44 in.lbf) for bolt
b. Connect the air hose and ventilation hose together.
11. CHECK FOR FUEL LEAKS
12. INSTALL V-BANK COVER
a. Install the V-bank cover with the 2 nuts.
Torque: 5.0 N.m(51 kgf.cm, 44 in.lbf)
13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
14. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
15. ADD ENGINE COOLANT
16. CHECK FOR ENGINE COOLANT LEAKS