Disassembly and Assembly
INTAKE MANIFOLDDISASSEMBLY
2200 cc MODEL
1) Disconnect engine ground terminal from intake manifold.
2) Disconnect EGR vacuum hose from EGR valve. (AT vehicles)
3) Disconnect back pressure hose from pipe (AT vehicles)
4) Disconnect BIT hoses from EGR solenoid valve and intake manifold. (AT vehicles)
5) Remove BIT with BTP holder bracket. (AT vehicles)
6) Remove EGR valve. (AT vehicles)
7) Disconnect connectors from throttle position sensor, ignition coil, fuel injectors, idle air control solenoid valve, purge control solenoid valve and EGR solenoid valve. (AT vehicles)
A) EGR solenoid valve (AT vehicles)
B) Throttle position sensor
C) Idle air control solenoid valve
D) Purge control solenoid valve
8) Remove engine harness from intake manifold.
9) Remove idle air control solenoid valve from intake manifold.
10) Remove throttle body from intake manifold.
11) Remove ignition coil.
12) Remove fuel pipes, etc. from intake manifold.
A) Pressure regulator
B) Fuel pipe ASSY
13) Remove fuel injector pipes.
14) Remove EGR solenoid valve (AT vehicles) and purge control solenoid valve.
2500 cc MODEL
1) Disconnect engine ground terminal from intake manifold.
2) Disconnect EGR vacuum hose from EGR valve.
3) Disconnect back pressure hose from pipe.
4) Disconnect BIT hoses from EGR solenoid valve and intake manifold.
5) Remove BIT with BTP holder bracket.
6) Remove EGR valve.
7) Disconnect connectors from throttle position sensor, ignition coil, fuel injectors, idle air control solenoid valve, purge control solenoid valve and EGR solenoid valve.
A) EGR solenoid valve
B) Throttle position sensor
C) Idle air control solenoid valve
D) Purge control solenoid valve
E) Harness band
8) Remove engine harness from intake manifold.
9) Remove idle air control solenoid valve from intake manifold.
10) Remove throttle body from intake manifold.
11) Remove ignition coil.
12) Remove fuel pipes, etc. from intake manifold.
A) Pressure regulator
B) Fuel pipe ASSY
13) Remove fuel injector pipes.
14) Remove EGR solenoid valve and purge control solenoid valve.
ASSEMBLY
2200 cc MODEL
1) Install EGR solenoid valve (AT vehicles) and purge control solenoid valve.
2) Install fuel injector pipes.
3) Assemble fuel pipes, etc. to intake manifold.
A) Pressure regulator
B) Fuel pipe ASSY
4) Install ignition coil.
5) Assemble throttle body to intake manifold.
Tightening torque: 22 ± 2 (2.2 ± 0.2 kg-m, 15.9 ± 1.4 ft. lb)
CAUTION: Replace gasket with a new one.
6) Install idle air control solenoid valve to intake manifold.
Tightening torque: 6.4 ± 0.5 N.m (0.65 ± 0.05 kg-m, 4.7 ± 0.4 ft. lb)
CAUTION: Replace gasket with a new one.
7) Install engine harness onto intake manifold.
8) Connect connectors to throttle position sensor, ignition coil, fuel injectors, idle air control solenoid valve, purge control solenoid valve and EGR solenoid valve. (AT vehicles)
A) EGR solenoid valve (AT vehicles)
B) Throttle position sensor
C) Idle air control solenoid valve
D) Purge control solenoid valve
9) Install EGR valve. (AT vehicles)
Tightening torque: 19 ± 1.5 N.m (1.9 ± 0.15kg-m, 13.7 ± 1.1 ft. lb)
CAUTION: Replace gasket with a new one.
10) Install BIT with BIT holder bracket. (AT vehicles)
11) Connect BIT hoses from EGR solenoid valve and intake manifold. (AT vehicles)
12) Connect back pressure hose from pipe. (AT vehicles)
13) Connect EGR vacuum hose from EGR vale.(AT vehicles)
14) Connect engine ground terminal to intake manifold.
Tightening torque: 19 ± 1.5 N.m (1.9 ± 0.15kg-m, 137 ± 1.1 ft. lb)
2500 cc MODEL
1) Install EGR solenoid valve and purge control solenoid valve.
2) Install fuel injector pipes.
3) Assemble fuel pipes, etc. to intake manifold.
A) Pressure regulator
B) Fuel pipe ASSY
4) Install ignition coil.
5) Assemble throttle body to intake manifold.
Tightening torque: 22 ± 2 N.m (2.2 ± 0.2 kg-m, 15.9 ± 1.4 ft. lb)
CAUTION: Replace gasket with a new one.
6) Install idle air control solenoid valve to intake manifold.
Tightening torque: 6.4 ± 0.5 N.m (0.65 ± 0.05 kg-m, 4.7 ± 0.4 ft. lb)
CAUTION: Replace gasket with a new one.
7) Install engine harness onto intake manifold.
8) Connect connectors to throttle position sensor, ignition coil, fuel injectors, idle air control solenoid valve, purge control solenoid valve and EGR solenoid valve.
A) EGR solenoid valve
B) Throttle position sensor
C) Idle air control solenoid valve
D) Purge control solenoid valve
E) Harness band
9) Install EGR valve.
Tightening torque: 19 ± 1.5 N.m (1.9 ± 0.15 kg-m, 13.7 ± 1.1 ft. lb)
CAUTION: Replace gasket with a new one.
10) Install BIT with BIT holder bracket.
11) Connect BIT hoses from EGR solenoid valve and intake manifold.
12) Connect back pressure hose from pipe.
13) Connect EGR vacuum hose from EGR valve.
14) Connect engine ground terminal to intake manifold.
Tightening torque: 19 ± 1.5 N.m (1.9 ± 0.15 kg-m, 13.7 ± 1.1 ft. lb)