REPAIR INSTRUCTIONS ON-VEHICLE SERVICE

Transcription

1 1G-6 REPAIR INSTRUCTIONS ON-VEHICLE SERVICE AIR CLEANER AND INTAKE AIR DUCT Cover Element Housing Specifications Element Type Service Interval Dry-Element Type * Initial cleaning: 5,000 km, Clean or change every 10,000 km as required. However, change every 30,000 km. * If the vehicle is operated under severe condition (short distance driving, extensive idling or driving in dusty condition): More frequent maintenance is required.

2 1G-7 Air Cleaner Element - Replacement Preceding Work: Disconnection of negative battery cable 1. Disconnect the HFM sensor connector. 2. Loosen the locking clamp and remove the intake duct. 3. Unscrew the screws and remove the air cleaner cover. 4. Remove the air cleaner element. Clean or replace the element as required.

3 1G-8 Air Cleaner Housing - Removal and Preceding Work: Removal of air cleaner cover 1. Set aside the return hose and remove the coolant reservoir bolts. 2. Remove the air cleaner housing bolts. 3. Install in the reverse order of removal. Air Cleaner Housing/Element - Check 1. Check the air cleaner body, cover and packing for deformation, corrosion and damage. 2. Check the air duct for damage. 3. Check the air cleaner element for clogging, contamination and damage. If the element is partially clogged, remove the dust or foreign materials with the compressed air. If the contamination is severe, replace it with new one. Also, be careful not to contaminate during the replacement. 4. Check the air cleaner housing for clogging, contamination and damage. 5. If the inside of housing is contaminated, remove the contaminants. Notice When cleaning the air cleaner with compressed air, direct the air from inside (engine) to outside (ambient air). Otherwise, contaminants can get into the engine.

4 1G-9 INTAKE MANIFOLD Preceding Work: Removal of fuel rail Removal of battery Removal of canister 1. Bolt (M6 X 40, 4 pieces) 9 ~ 11 Nm (80 ~ 97 lb-in) 2. Softcap 3. Resonance flap 4. Gasket... replace 5. Upper intake manifold 6. Bolt (M8 X 50, 9 pieces) ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) 7. Gasket... replace 8. Blow-by hose 9. Blow-by hose 10. Clamp 11. Blow-by nipple 12. Inlet air housing 13. Bolt (M6 X 40, 4 pieces) 9 ~ 11 Nm (80 ~ 97 lb-in) 14. Throttle body-electric 15. Gasket... replace 16. Lower intake manifold 17. Bolt (M8 X 40, 4 pieces) ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) 18. Nipple 19. Seal ring 20. Connector 21. Connection house 22. Clamp

5 1G-10 RESONANCE FLAP 1. Soft cap (2) 2. Bolt (M6 X 40, 4 piecesc)... 9 ~ 11 Nm (80~ 97 lb-in) 3. O-ring 4. Vacuum hose 5. Resonance flap 6. Gasket... Replace Removal & Procedure 1. Remove the 2 soft caps (1). 2. Remove the upper resonance flap coupling after removing 4 bolt (2). 9 ~ 11 Nm (80 ~ 97 lb-ft) 3. Check the O-ring (3) and replace it if necessary. 4. Remove the lower resonance flap (5). 5. Replace the gasket (6). 6. should follow the removal procedure in the reverse order.

6 1G-11 EXHAUST LINE 1. Front exhaust pipe 2. Muffler 3. Tail exhaust pipe 4. Gasket... replace 5. Gasket... replace 6. Hanger 7. Hanger 8. Heat protector No Heat protector No Heat protector No Heat protector No Bolt ~ 28 Nm (11 ~ 21 lb-ft) 13. Nut ~ 47 Nm (21 ~ 35 lb-ft) 14. Nut... 8 ~ 18 Nm (6 ~ 13 lb-ft) 15. Screw 16. Oxygen sensor

7 1G-12 Removal & Procedure 1. Disconnect the oxygen sensor electrical connectors. 2. Remove the exhaust manifold to front exhaust pipe nuts. Notice 3. Remove the oxygen sensor and hanger from the front exhaust pipe. 15 ~ 28 Nm (11 ~ 21 lb-ft) 4. Remove the front exhaust pipe to muffler nuts. 28 ~ 47 Nm (21 ~ 35 lb-ft) 5. Remove the muffler to tail exhaust pipe nuts. 28 ~ 47 Nm (21 ~ 35 lb-ft) 6. Remove the Mounting hunger and muffler. 7. Remove the mounting hanger and tail exhaust pipe. 8. Check the muffler and pipes for holes, damage, open seams, or other deterioration. Which could permit exhaust fumes to seep into the passenger compartment or the trunk. 9. should follow the removal procedure in the reverse order.