Repair Procedures

Removal and Installation

1. Disconnect the battery negative terminal (A).

Tightening torque:
4.0 - 6.0 N.m (0.4 - 0.6 kgf.m, 3.0 - 4.4 lb-ft)

2. Remove the engine cover (B).




3. Remove the air cleaner assembly.
(1) Disconnect the breather hose (A) and the BARO(Barometric pressure) sensor connector (B).
(2) Disconnect the air intake hose and then remove the air cleaner assembly (C).

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




4. Remove the under cover.
5. Loosen the drain plug (A), and drain the coolant. Remove the radiator cap to speed draining.

WARNING:
Never remove the radiator cap when the engine is hot.
Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.




6. Disconnect the wiring connectors, harness clamps and hoses from the engine.
(1) Power steering pump oil pressure switch.
(2) RH front, rear oxygen sensor connector (A) and loosen the power steering hose mounting bolts (B).




(3) VIS connector (A).
(4) RH exhaust camshaft OCV connector (B).
(5) RH ignition coil connector (C).
(6) RH injector connector (D).




(7) LH exhaust camshaft OCV connector (A).
(8) LH/RH intake camshaft OCV connector (B).
(9) Oil pressure switch connector (C).
(10) Knock sensor connector (D).
(11) Condenser connector (E).
(12) Ground (F).
(13) LH front oxygen sensor connector (G).




(14) Alternator connector (A).




(15) LH ignition coil connectors (A).
(16) LH injector connectors (B).
(17) LH intake CMPS connector (C).




(18) MAP sensor connector (A).
(19) PCSV connector (B).




(20) RH intake CMPS connector (A)
(21) ETC connector (B)
(22) OTS connector (C)
(23) Knock sensor connector (D)
(24) RH exhaust CMPS connector (E)




7. Disconnect the PCSV hose (A), fuel hose (B), brake booster vacuum hose (C), PCV hose (D).




8. Disconnect the throttle body coolant hoses (A).
9. Remove the throttle body mounting bolt (B).

Tightening torque :
18.6 - 23.5N.m (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)




10. Remove the surge tank stay (A).

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




11. Remove the surge tank (A).

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




12. Remove the delivery pipe & injector assembly (A).




13. Remove the intake the manifold (A).





NOTE:
Cover the inlet of cylinder head with a clean cloth or vinyl cover to prevent foreign materials from entering the engine.

14. Installation is reverse order of removal.
Tighten the intake manifold bolts and nuts, in several passes as below.

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