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.

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

2. Remove the engine cover (A).
3. Remove the strut bar (B).




4. Loosen the drain plug and drain the engine coolant.
5. Remove the intake air hose and air cleaner assembly.
(1) Remove the air duct (A).
(2) Disconnect the Barometric Pressure Sensor (BPS) 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)




6. Disconnect the brake booster vacuum hose (A).




7. Disconnect the engine wiring connectors and harness protector on the surge tank.
8. Disconnect the purge control solenoid valve (PCSV) hoses (A), positive crankcase ventilation (PCV) and the throttle body coolant hoses (C).




9. Remove the surge tank (A).

Tightening torque
Long bolt (2ea) :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
Short bolt (4ea) :
18.6 - 23.5N.m (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)
Nut (2ea) :
18.6 - 23.5N.m (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)




10. 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)




11. Disconnect the water hose & pipe (A) and then remove the intake manifold (B).





WARNING:
- 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.

12. 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





NOTE:
- When installing, replace with new gaskets.
- When replacing the LH gasket, tighten the screw(A) with specified torque.

Tightening torque :
2.9 - 3.9 N.m (0.3 - 0.4 kgf.m, 2.2 - 2.9 lb-ft)