Fuel Delivery and Air Induction: Service and Repair

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]

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 vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
- Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See Before Service Precaution.)

1. Disconnect the negative battery cable.

2. Remove the charge air cooler duct.

3. Remove the battery and battery tray. (See Removal and Replacement.)

4. Remove the under cover.

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

7. Add the engine coolant to the cooling system filler neck and the coolant reserve tank to replace that during servicing. (Turbocharger not removed)

8. Refill the engine coolant. (Turbocharger removed)

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

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

11. Complete the "AFTER SERVICE PRECAUTION". (See After Service Precaution.)









Resonance Chamber Removal Note

1. Remove the mudguard.

2. Remove the resonance chamber.

Air Hose Removal Note

1. Disconnect the variable swirl shutter valve switch connector.

2. Disconnect the fuel injector harness connector.

3. Disconnect the ventilation hose connected to the air hose.

4. Remove the air hose.

Air Duct Removal Note

1. Disconnect the wastegate control solenoid valve connector.

2. Disconnect the purge solenoid valve connector.

3. Disconnect the EGR valve connector.

4. ATF gage pipe out of the way.

5. Remove the air duct.

Throttle Body Removal Note

Turbocharger not removed

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.

NOTE:
- If the turbocharger is not removed at the same time (if only throttle body is removed), remove the throttle body without draining the engine coolant.

1. Disconnect the throttle body connector.

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

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

4. Remove the throttle body.

Turbocharger removed

NOTE:
- If the turbocharger is removed at the same time, drain the engine coolant and remove the throttle body.

1. Disconnect the throttle body connector.

2. Drain the engine coolant before disconnect the water hose. (See Service and Repair.)

3. Remove the throttle body.

Intake Manifold Removal Note

1. Remove the fuel delivery pipe cover.






2. Disconnect the quick connector connected to the intake manifold.

3. Remove the EGR pipe.

4. Disconnect the variable swirl solenoid valve connector.

5. Disconnect the OCV connector.

6. Disconnect the PSP switch connector.

7. Remove the oil level gauge pipe. (See Service and Repair.)

8. Remove the splash shield (RF).

9. Remove the drive belt. (See Service and Repair.)

10. Set the power steering oil pump out of the way.

11. Disconnect the fuel pressure sensor connector.

12. Disconnect the vacuum hose connected between the intake manifold and the master cylinder from the intake manifold.

13. Disconnect the MAP sensor connector.

14. Remove the intake manifold installation bolts.

15. Disconnect the evaporative hose connected between the intake manifold and the PCV valve from the intake manifold.

16. Remove the intake manifold.

Turbocharger Removal Note

1. Remove the middle pipe. (See Service and Repair.)

2. Disconnect the HO2S connector.

3. Remove the front pipe. (See Service and Repair.)

CAUTION:
- When removing the cowl grille, a part or tool may hit the edge of the windshield and could damage it. Protect the windshield by covering it with a clean rag to prevent damage to the windshield.

4. Remove the cowl grille. (See Cowl Grille Removal/Installation.)

5. Remove the windshield wiper motor.

6. Remove the cowl panel.

7. Remove the insulator (Exhaust manifold upper side). (See Service and Repair.)

8. Set the generator out of the way. (See Removal and Replacement.)

9. Remove the insulator (Exhaust manifold lower side). (See Service and Repair.)

10. Disconnect the A/F sensor connector.

11. Remove the insulator (WU-TWC top side). (See Service and Repair.)

12. Remove the vacuum hose (Brake master back side).

13. Remove the A/F sensor. (See Service and Repair.)

14. Remove the WU-TWC. (See Service and Repair.)

15. Remove the oil pipes, water pipe, and insulator.






16. Remove the turbocharger.






Turbocharger Installation Note

1. Install the turbocharger.






Tightening torque
- 38-51 Nm {3.9-5.2 kgf-m, 29-37 ft-lbf}

2. Install the WU-TWC. (See Service and Repair.)

3. Install the A/F sensor. (See Service and Repair.)

4. Tight the oil pipe installation bolt while the stopper of the oil pipe is faced to the installation area, then install the insulator.






5. Install the oil pipe and water pipe, then insert the water hose until it reaches the stopper.






Wastegate Control Solenoid Valve Installation Note

1. Install the wastegate control solenoid valve.

Tightening torque
- 7.8-10.8 Nm {80-110 kgf-cm, 70-95 in-lbf}





2. Install the hose as shown in the figure.

Throttle Body Installation Note

1. Temporarily tighten the throttle body to the intake manifold.

2. Tighten the throttle body installation bolts in the order shown in the figure.






Tightening torque
- 8-11.5 Nm {82-117 kgf-cm, 71-101 in-lbf}

3. Remove the plug from the engine coolant hose and install the water hose to the throttle body quickly. (Turbocharger not removed)

4. Install the water hose to the throttle body. (Turbocharger removed)

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.