Intake Manifold: Service and Repair

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]

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", while referring to the "BEFORE SERVICE PRECAUTIONS".

1. Remove the battery cover. Removal and Replacement

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. Add the engine coolant to the cooling system filler neck and the coolant reserve tank to replace that during servicing.

6. Inspect the engine coolant level. Engine Coolant Level Inspection

7. Inspect for engine coolant leakage. Engine Coolant Leakage Inspection

Step 1 (Except 6MT)










Step 1 (6MT)










Step 2










Air Cleaner Cover Removal Note

1. Remove the MAF/IAT sensor. Service and Repair

2. Remove the air cleaner cover.

Fresh-air Duct Removal Note

1. Remove the front bumper. Removal and Replacement

2. Remove the fresh-air duct.

Throttle Body Removal Note

WARNING:
- Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
- When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

CAUTION:
- Do not plug the water hose with a sharp-edged object. Otherwise, the hose could be damaged.

1. Wrap a clean cloth around the cooling system cap and release the pressure by loosening the cap slowly.

2. Remove the water hose from the throttle body and plug the water hose quickly.

Dynamic Chamber Removal Note

1. Remove the plug hole plate. (See Service and Repair)

2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. Before Service Precaution

3. Remove the following parts:
a. Remove the front suspension tower bar (joint), (right side) and (left side). Service and Repair

b. Remove the wiper arm and blade. Service and Repair

c. Remove the cowl grille. Cowl Grille Removal/Installation

d. Remove the side cowl grille. Side Cowl Grille Removal/Installation

e. Move the cooler pipe No.3 and heater pipe slightly out of the way.






f. Remove the service hole cover.






4. Disconnect the heater hose and move the heater pipe slightly out of the way.






5. Disconnect the heater hose and move the heater hose slightly out of the way.






6. Remove the harness bracket.






7. Remove the under cover. Front Suspension - Transverse Member Removal/Installation

8. Disconnect the variable intake air solenoid valve connector, variable tumble solenoid valve connector (AT), EGR valve connector, CMP sensor connector and PSP switch connector.

9. Disconnect the ignition coil connector and fuel injector connector and move the harness slightly out of the way.

10. Disconnect the quick release connector from the fuel distributor. Quick Release Connector Removal/Installation

11. Remove the fuel distributor. Service and Repair

12. Disconnect the water hose from the EGR valve.

13. Disconnect two water hoses from the thermostat.

14. Remove the heater hose and heater pipe from the dynamic chamber.

15. Remove the variable intake air solenoid valve. Variable Intake Air Solenoid Valve Removal/Installation

16. Remove the variable tumble solenoid valve (AT). Variable Tumble Solenoid Valve Removal/Installation

17. Remove the dynamic chamber installation bolts.

18. Remove the EGR pipe.






19. Disconnect the connector from the A/C compressor.

20. Disconnect the KS connector.

21. Move the vacuum hose between the purge solenoid valve and the charcoal canister slightly out of the way.

22. Move the clutch release cylinder slightly out of the way. (MT) Removal and Replacement

23. Disconnect the evaporative hose with the dynamic chamber raised.






24. Remove the dynamic chamber.

25. Remove the variable intake air shutter valve actuator. Variable Intake Air Shutter Valve Actuator Removal/Installation

26. Remove the MAP sensor. Service and Repair

Intake Manifold Removal Note

1. Remove the intake manifold.

2. Remove the variable tumble shutter valve actuator (AT). Variable Tumble Shutter Valve Actuator Removal/Installation

Throttle Body Installation Note

1. Temporarily tighten the throttle body to the dynamic chamber.

2. Tighten the bolts in the order as shown in the figure.






Throttle body tightening torque
- 8.0-11.5 Nm {82-110 kgf-cm, 71-100 in-lbf}

3. Remove the plug from the engine coolant hose and install the water hose to the throttle body quickly.