Repair Procedures

Removal and Installation

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 (A).

Tightening torque :
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)




2. Remove the engine cover (A), engine side covers (B) and the radiator grill upper cover (C).




3. Loosen the drain plug and drain the engine coolant.
4. Remove the intake air hose and air cleaner assembly.
(1) Remove the air duct (A).
(2) Disconnect the MAFS connector (B).
(3) Disconnect the breather hose (C).
(4) Disconnect the vacuum hose (D).
(5) Remove the intake air hose (E) and air cleaner assembly (F).

Tightening torque
Hose clamp bolt :
2.9 - 4.9 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)
Air cleaner assembly bolts :
7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb-ft)




5. Disconnect the fuel hose (A), PCSV hose (B) and the intensifier hose (C).




6. Disconnect the engine wiring harness connectors and hoses.
(1) RH ignition coil connector (A)
(2) RH knock sensor connector (B)




(3) RH exhaust oil control valve (OCV) connector (A)
(4) RH injector connector (B)
(5) VIS solenoid valve connector (C)




(6) LH exhaust oil control valve (OCV) connector (A)
(7) LH/RH intake oil control valve (OCV) connector (B)
(8) Oil pressure switch connector (C)
(9) LH Injector connector (D)
(10) Ignition coil condenser connector (E)
(11) LH knock sensor connector (F)




(12) ETC connector (A), PCV hose (B)
(13) RH exhaust camshaft position sensor (CMPS) connector (C)
(14) Water temperature sensor (D)
(15) Ignition coil condenser connector (E)
(16) RH front oxygen sensor connector (F)




(17) Fuel pump connector (A)
(18) LH ignition coil connector (B)
(19) LH exhaust camshaft position sensor (CMPS) connector (C)
(20) LH front oxygen sensor connector (D)




(21) PCSV connector (A)
(22) LH intake camshaft position sensor (CMPS) connector (B)
(23) MAP sensor connector (C)
(24) Oil temperature sensor connector (D)
(25) RH intake camshaft position sensor (CMPS) connector (E)




7. Remove the surge tank (A).

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




8. Remove the breather pipe & hose (A).

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




9. Remove the high pressure fuel tube bracket bolt (A).

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




10. Disconnect the water hose (C) & pipe (A) and then remove the intake 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.

11. Installation is reverse order of removal.

NOTE:
Tighten the intake manifold bolts, in several passes as below.

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

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