Fuel Delivery and Air Induction: Service and Repair

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L5]

WARNING:
- A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake air system.
- Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure".

CAUTION:
- Parts for engines manufactured in Mexico and Hiroshima cannot be used interchangeably as the engine will not operate correctly resulting in a serious malfunction. To prevent this, when replacing parts refer to the 'VEHICLE IDENTIFICATION NUMBER (VIN) CODE' table below and verify the engine's place of manufacture before performing the servicing. (See Vehicle Identification Number (VIN) Code)

1. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution

2. Disconnect the negative battery cable. Removal and Replacement

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution
Step 1










Step 2










Resonance Chamber Removal Note

1. Remove the front mudguard (LH). Service and Repair

2. Remove the resonance chamber.

Water Hose Removal Note

1. Drain the engine coolant. Service and Repair

2. Disconnect the water hose.

Intake Manifold Removal Note

1. Remove the aerodynamic under cover No.2. Aerodynamic Under Cover No.2 Removal/Installation

2. Remove the coolant reserve tank. Service and Repair

3. Remove all clips for securing wiring harnesses from the intake manifold.

4. Disconnect the vacuum hoses connecting the intake manifold.

5. Remove the fuel distributor and fuel injector a as single unit. Service and Repair

6. Remove the intake manifold.

Vacuum Hose Installation Note

1. Install the vacuum hose shown in the figure.






Throttle Body Installation Note

1. Tighten the installation bolts in the order shown in the figure.






Throttle body tightening torque
- 8-11 Nm {82-112 kgf-cm, 71-97 in-lbf}

Fresh-Air Duct Installation Note

CAUTION:
- If the coolant reserve tank hose is installed to the clips at the wrong locations, the hose may contact other parts and be damaged. When reinstalling the coolant reserve tank hose to the clips, install it to the original locations according to the following procedure.






1. Install the coolant reserve tank hose to the clips as shown in the figure.






Air Cleaner Case Installation Note

CAUTION:
- Before assembling the air cleaner, verify that the rubber mounts have not fallen off from the air cleaner bracket (3 locations).
- Always install the air cleaner case using the following procedure.

NOTE:
- When inserting the rubber mounts into the air cleaner case, soapy water can be applied.

1. Verify that the rubber mounts are set in the air cleaner bracket (3 locations).

2. Install the projections on the frame side (2 locations).

3. Verify that the projections on the frame side are installed securely.

4. Install the projection on the engine side (remaining location).

5. Verify that the projection on the engine side installed securely.