Instructions For Kit # 1 - Throttle Body and PCV Relocation

Contents For Kit # 1 (P/N) 26700-22000-D):

INSTRUCTIONS FOR KIT # 1 - THROTTLE BODY AND PCV RELOCATION:

1.5 L Accent: Produced through January 31, 2001

1. Record the customer's preset radio stations, then disconnect the battery's negative (-) terminal.

2. Disconnect the following:

a. Mass Air Flow, Idle Speed Control, and Throttle Position Sensor connectors.

b. The breather hose at the air duct.

3. Loosen the hose clamp at the throttle body to loosen the duct.

4. Unsnap the latches for the upper air filter housing.

5. Remove the upper air filter housing, Mass Air Flow, and air duct from the throttle body as a single unit.

6. Remove the capscrews and mounting nuts, then remove the throttle body from the vehicle.

7. Remove the canister purge valve hose at the throttle body, and disconnect the throttle cable.

8. Place a shop rag over the end of the surge tank to capture the expansion plug.





9. Insert a long punch (Snap-On PPB1226 or equivalent) through the bore of the surge tank. Using a hammer, gently tap the expansion plug out of the opposite end (passenger side) of the surge tank.

CAUTION:
Be careful not to hit the punch onto the aluminum surge tank. Be sure the punch is directly on the expansion plug.

10. Clean the bore of the surge tank with a shop rag and solvent.





11. Inspect the PCV installation jig to see if a "punch mark" (indicating "TOP") has already been stamped. The "TOP" punch mark will help orient the new PCV elbow in later steps. If there is no mark, make the mark as follows:





A. Referring to the figures, measure 0.5" from the edge of the tool and make a pencil mark on the outside of the jig.





B. Permanently make a mark using a punch. Make a small paint dot to help identify location of the punch mark.





12. Apply a thin bead of Loctite 603 (or Permatex 60940) around the diameter of the new aluminum PCV elbow and spread the Loctite to coat the outer surface (P/N 28312-22700-D, 1.5L SOHC 30.25 mm diameter).

NOTE:
Use the Loctite sparingly. Applying too much will not allow the product to cure properly.

13. Insert the PCV elbow into the hole where the expansion plug was removed.

NOTE:
The new PCV elbow is already connected to the new PCV hose. Do not separate these pieces.





14. Orient the PCV installation jig with the "top" pointed up and place the jig over the PCV elbow. Using a small hammer, gently tap the PCV elbow into the surge tank until the installation jig is flush with the surge tank.

NOTE:
By orienting the installation jig with the "top" mark up, the finished angle of the PCV elbow will be 10° above horizontal (this is the desired installation angle).

15. Wipe off any excess Loctite 603.

16. Mix a small amount of 3M adhesive (P/N DP460) and apply it to perimeter of the PCV elbow and surge tank. Use a small brush to get the area behind the elbow/hose.

17. Remove the PCV hose from the surge tank and PCV valve, and discard. Save the hose clamps.

18. Insert the rubber vacuum cap (P/N 28325-22070) over the hose fitting on the surge tank. Install one of the hose clamps from previous step over the rubber vacuum cap.





19. Install the PCV valve insulation (P/N 26719-23010) over the PCV valve.

20. Install the PCV hose (P/N 26721-22611-D) onto the PCV valve.





21. Use strap (P/N 17993-22000) and make two marks; one at 160 mm (6.3 inches) and one at 175 mm (6.9 inches). The marks on the strap will be used as a template in the next step.





22. With the marked strap and measuring from the dash panel, make a mark on the driver side heater hose that matches the 175 mm mark.

23. With the marked strap and measuring from the dash panel, make a mark on the passenger side heater hose that matches the 160 mm mark.

24. Relieve any cooling system pressure by removing the radiator cap. Reinstall the cap after the pressure is relieved.

25. Place a drain pan under the engine approximately where the heater hoses are located.

26. Cut the passenger side heater hose at the mark with heater hose cutters (Snap On P/N PWC60 or equivalent). Slide a 1/2" hose clamp over each end of the cut hose.

27. Install the 180 mm hose (P/N 25414-22955-D) onto the "T" connector (P/N 25412-22955-D).





28. Install the 180 mm hose/ "T" connector assembly into both ends of the cut heater hose. Orient the tee so that the smaller hose points in the direction of the throttle body. Slide the 1/2" hose clamps over the tee section of the heater hose.

29. Cut the driver side heater hose at the mark with heater hose cutters (Snap On P/N PWC60 or equivalent). Slide a 1/2" hose clamp over each end of the cut hose.

30. Install the 160 mm hose (P/N 25413-22955-D) onto the "T" connector (P/N 2541 2-22955-D).

31. Install the 160 mm hose/ "T" connector assembly into both ends of the cut heater hose. Orient the tee so that the smaller hose points in the direction of the throttle body. Slide the 1/2" hose clamps over the tee section of the heater hose.

32. Transfer the ISC and TPS from the old throttle body to the new throttle body. Install a new ISC gasket (P/N 35156-33271).

33. Install a new throttle body gasket (P/N 35101-22601) on the intake manifold.





34. Slide the throttle body over the studs and connect the following:

a. Canister purge valve hose.

b. Two coolant hoses.

C. ISCA harness connector.

d. TPS harness connector.

e. Throttle cable.

35. Reinstall the upper stud nuts and lower mounting capscrews (be sure to install the wire harness bracket under the left side capscrew). Torque the fasteners to 11-15 lb.-ft. (15-20 N-m).

36. Secure the two coolant hoses to the main wiring harness using the supplied hose strap (P/N 17993-19000).

37. Reinstall the upper air filter housing, Mass Air Flow, and air duct from the throttle body as a single unit.

38. Reassemble the following:

a. Mass Air Flow connector

b. The breather hose at the air duct.

c. Tighten the hose clamp at the throttle body.

d. Snap the latches for the upper air filter housing.

39. Refill the cooling system with coolant.

40. Reconnect the battery's negative (-) terminal, program the customer's preset radio stations, and reset the clock to the correct time.

41. Start the engine and check to be certain no coolant or vacuum leaks are present.

42. Destroy the removed throttle body to render it useless and unusable prior to discarding.