Instructions For Kit # 2 and # 3 - PCV Relocation

CONTENTS OF KIT 2 (P/N 26700-22100-D) and KIT 3 (P/N 26700-26100-D):

1.5 L Accent: From February 1, 2001 - February 13, 2001
1.6 L Accent: Produced through June 5, 2001 (through June 4, 2001 for 4 door models)

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

2. Disconnect the Mass Air Flow (1.5L only) connector and 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 (if applicable), and air duct from the throttle body as a single unit.





6. Use a bungee cord (or equivalent) to hold open the throttle plate of the throttle body.





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





8. Insert a long punch (Snap-On P/N 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 into the aluminum Surge Tank. Be sure the punch is directly on the Expansion Plug.

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

10. 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, see Step 11 in KIT # 1 for directions.





11. Apply a thin bead of Loctite 603 (or Permatex 60940) around the diameter of the new aluminum PCV elbow and spread the Permatex to coat the outer surface:

KIT # 2, P/N 28312-22700-D 30.25 mm diameter; 1 .5L SOHC

KIT # 3, P/N 28312-26700-D 35.29 mm diameter; 1.6L DOHC.

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





12. 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.





13. Orient the PCV installation jig with the "top" pointed up and place the jig over the PCV elbow. Using a small mallet, 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 100 above horizontal (this is the desired installation angle).

14. Wipe off any excess Loctite 603.





15. 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.

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

17. 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.

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





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

20. Remove the bungee cord from the throttle body.

21. Reinstall the upper air filter housing, Mass Air Flow (if applicable), and air duct from the throttle body as a single unit.

22. Reassemble the following:

a. Mass Air Flow connector (if applicable).

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.

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

24. Start the engine and check that no vacuum leaks are present.