Repair Procedures

Removal

CAUTION:
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:
- Mark all wiring and hoses to avoid misconnection.

1. Disconnect the battery negative cable.
2. Loosen the drain plug and drain the engine coolant.
3. Remove the engine cover (A).

NOTE:
Remove the engine cover bolts as following method.




4. Remove the air duct (A).




5. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the MAFS connector (A).
(2) Disconnect the breather hose (B).
(3) Remove the resonator (C).
(4) Remove the intake air hose (D) and air cleaner assembly (E).




6. Remove the fuel hose (A).




7. Disconnect the brake vacuum hose.




8. Disconnect the engine wiring connectors.
(1) Disconnect the power steering oil pressure switch connector(A) and RH knock sensor connector(B).




(2) Disconnect the MAP sensor connector (A), ETC connector (B), RH exhaust OCV connector (C), RH injector connector (D) and RH ignition coil connector (E).




(3) Disconnect the LH knock sensor connector (A), LH/RH intake OCV connector (B) and LH exhaust OCV connector (C).




(4) Disconnect the LH injector connector (A) and LH ignition coil connector (B).




(5) Disconnect the oil pressure switch connector (A),LH exhaust camshaft CMP sensor connector (B) and LH oxygen sensor connector (C).




(6) Disconnect the LH intake camshaft CMP sensor connector (A) ,RH intake camshaft CMP sensor connector (B) and condenser connector (C).




(7) Disconnect the VIS solenoid valve connector (A),PCSV connector (B) and RH oxygen sensor connector (C).




(8) Disconnect the water temperature sensor connector (A) and oil temperature sensor connector (B).




(9) Disconnect the RH exhaust camshaft CMP sensor connector (A).




9. Remove the fuel pipe (A) and vacuum pipe (B).




10. Remove the throttle body coolant hoses (A) and PCV hose (B).




11. Remove the surge tank stay (A).




12. Remove the surge tank assembly (A).




13. Disconnect the RH injector connector (A).




14. Disconnect the water vent hose (A) and then remove the intake the manifold (B).

CAUTION:
- Be sure to drain the engine coolant before removing the intake manifold.
- If any coolant drained from the cylinder head vent hole has entered the intake port. This can potentially lead to engine trouble.





Installation

1. Install the intake the manifold (B) with a new gasket, and connect the water vent hose (A).

CAUTION:
- Be sure to drain the engine coolant before removing the intake manifold.
- If any coolant drained from the cylinder head vent hole has entered the intake port. This can potentially lead to engine trouble.

Tightening torque
Step 1: 3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
Step 2:
Nut- 18.62 - 23.52N.m (1.9 - 2.4kgf.m, 13.74 - 17.36lb-ft)
Bolt -26.5 - 31.4N.m (2.7 - 3.2kgf.m, 19.5 - 23.1lb-ft)
Step 3: Repeat 2nd step twice or more.





a - h : 1st step order
1 - 8 : 2nd step order

NOTE:
Confirm the manifold gasket identification mark (LH, RH) and be careful of the installation direction.




2. Connect the RH injector connector (A).




3. Install the surge tank assembly (A).

Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)




4. Install the surge tank stay (A).

Tightening torque :
27.5 - 31.4N.m (2.8 - 3.2kgf.m, 20.3 - 23.1lb-ft)




5. Install the throttle body coolant hoses (A) and PCV hose (B).




6. Install the fuel pipe (A) and vacuum pipe (B).

Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)




7. Connect the engine wiring connectors.
(1) Connect the RH exhaust camshaft CMP sensor connector (A).




(2) Connect the water temperature sensor connector (A) and oil temperature sensor connector (B).




(3) Connect the VIS solenoid valve connector (A), PCSV connector (B) and RH oxygen sensor connector (C).




(4) Connect the LH intake camshaft CMP sensor connector (A) ,RH intake camshaft CMP sensor connector (B) and condenser connector (C).




(5) Connect the oil pressure switch connector (A), LH exhaust camshaft CMP sensor connector (B) and LH oxygen sensor connector (C).




(6) Connect the LH injector connector (A) and LH ignition coil connector (B).




(7) Connect the LH knock sensor connector (A), LH/RH intake OCV connector (B) and LH exhaust OCV connector (C).




(8) Connect the MAP sensor connector (A), ETC connector (B), RH exhaust OCV connector (C), RH injector connector (D) and RH ignition coil connector (E).




(9) Connect the power steering oil pressure switch connector(A) and RH knock sensor connector(B).




8. Connect the brake vacuum hose (A).
9. Install the fuel hose (A).

Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)




10. Install the intake air hose and air cleaner assembly.
(1) Install the intake air hose (D) and air cleaner assembly (E).

Tightening torque
Bolt (D) : 1.9 - 2.9N.m (0.2 - 0.3kgf.m, 1.4 - 2.2lb-ft)
Bolt (E) : 7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)

(2) Install the resonator (C).

Tightening torque
Bolt (C) : 7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)

(3) Connect the breather hose (B).
(4) Connect the MAFS connector (A).




11. Install the air duct (A).




12. Install the engine cover (A).

NOTE:
Install the engine cover bolts as following method.




13. Connect the battery negative cable.

NOTE:
- Refill engine coolant.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.
- Clean the battery posts and cable terminals with sandpaper. Assemble and, then apply grease to prevent corrosion.