Service Procedure
Service ProcedureParts Overview
No. 2 Cylinder Head Cover
Union-to-Connector Tube Hose
Fasteners
Air Tube
Duty Vacuum Switching Valve
No. 1 Fuel Vapor Feed Hose
No. 1 Vacuum Transmitting Hose
No. 2 Ventilation Hose
No. 1 Air Cleaner Hose
Plug
Clip
Ventilation Hose
Bolts
Throttle Body Gasket
Intake Air Connector Assembly
Diesel Throttle Body Gasket
Throttle Body Assembly
1. Remove the No. 2 cylinder head cover.
Caution
Lifting both the front and rear sides up at once will damage the cover.
1. Place both hands on the back of the cover, lift up the cover, and remove the two clips on the back.
2. Place both hands on the front of the cover, remove the two clips on the front, and then remove the cylinder head cover.
2. Remove the No. 1 air cleaner hose.
Note
Be sure to remove the clip to prevent it from falling out.
1. Separate the ventilation hose and remove the clip.
2. Loosen the two hose clamps and remove the No. 1 air cleaner hose.
3. Place protective tape (1) over the throttle body assembly opening to prevent foreign objects from entering it.
3. Remove the throttle body assembly.
Note
Dispose of the removed stud bolts. Do not disconnect the connector and water bypass hoses for the throttle body assembly.
1. Remove the two bolts and two nuts.
2. Remove the throttle body gasket from the intake manifold.
3. Place protective tape (1) over the intake manifold opening to prevent foreign objects from entering it.
4. Remove the air tube.
Note
Be sure to remove the clip to prevent it from falling out.
1. Separate the ventilation hose and remove the clip.
2. Remove the No. 1 vacuum transmitting hose (1) and 2 clips. Discard the hose and clips.
3. Remove the No. 1 fuel vapor feed hose (2). Discard the hose.
4. Disconnect the crank position sensor connector (1).
5. Separate the wire harness clamp (2).
Note
If the screw connecting the duty vacuum switching valve to the bracket cannot be removed, remove the duty vacuum switching valve by removing the bolt on the bracket.
6. Remove the screw (3).
7. Disconnect the two wire harness clamps (1).
8. Separate the duty vacuum switching valve with fuel vapor feed hose (2).
9. Separate the union to connector tube hose (3).
10. Remove the two bolts.
Note
Do not damage the crank position sensor and wire harness when removing the air tube.
11. Remove the air tube while ensuring that the tube does not come in contact with the crank position sensor and wire harness. Discard the air tube.
5. Install the NEW plug (2).
1. Install a NEW plug (2) to the intake manifold's No. 1 vacuum transmitting hose connection point (3).
2. Install a NEW clip (1) as shown in the illustration.
6. Connect the ventilation hose.
Connect the ventilation hose with the clip.
7. Install the air tube.
Note
Set the air tube underneath the wire harness as shown in the illustration. When installing the air tube, ensure that the wire harness does not pitch the air tube.
1. Temporarily install the NEW air tube.
Note
If the bracket for the duty vacuum switching valve was removed along with it, do not mistake the air tube bolt, which is 16 mm (0.62 in) in length, for the bracket bolt 20 mm, which is (0.78 in) in length. Install the 2 bolts. Tighten to 10 Nm(89 lb in).
2. Connect the union-to-connector tube hose (1).
3. Connect the duty vacuum switching valve with the fuel vapor feed hose (2).
4. Connect the two wire harness clamps (3).
Note
If the bracket for the duty vacuum switching valve was removed along with it, remove the new bracket connected to the new air tube, and install the duty vacuum switching valve to the air tube. Tighten to 5.9 Nm (52 lb in).
5. Install the vacuum switching valve with the screw (1).
6. Connect the wire harness clamp (2).
7. Connect the crank position sensor connector (3).
8. Install the throttle body assembly.
1. Remove the protective tape.
Align
2. Install the NEW throttle body gasket.
3. In the order shown, install a NEW intake air connector, NEW gasket, and then provisionally install the intake manifold with 4 NEW bolts.
4. Verify that the gasket has been properly installed.
Note
Ensure that the air intake connector is properly aligned with the throttle body by pulling upward on the air intake connector hose fitting while tightening the bolts. Failure to do this may result in a whistling noise during light throttle application.
Note
To ensure a tight seal with the gasket, pull up on the intake air connector as illustrated.
5. While pulling up the intake air connector, tighten the 4 bolts to 10 Nm(89 lb in).
9. Inspect the water hose clearance (for automatic transmission vehicles only).
If after installing the throttle, the water bypass hose interferes with the transmission oil filler tube or if the space between the water hose and transmission oil filler tube is small, twist the water hose as needed to create at least 5 mm (0.20 in) or more of space.
10. Install the No.1 vacuum transmitting hose.
1. With a NEW clip, install the NEW No. 1 vacuum transmitting hose to the air tube so that its yellow paint mark (1) faces outward.
2. With a NEW clip, install the NEW No. 1 vacuum transmitting hose to the intake air connector so that its white paint mark (2) faces upward.
3. If the space between the No. 1 vacuum transmitting hose and wire harness is less than 5 mm (0.20 in), follow the steps given below and adjust the wire harness to create more space.
4. Separate the indicated bracket.
5. Open the clamp, slide the hose about 1 to 2 ribs towards the left side of the vehicle and close the clamp.
6. Reconnect the bracket to the intake manifold, check; check the spacing.
11. Install the No. 1 fuel vapor feed hose.
1. Install the NEW No. 1 fuel vapor feed hose to the air tube so that its yellow paint mark (1) faces outward.
2. Install the NEW No. 1 fuel vapor feed hose to the intake air connector so that its white paint mark (2) faces front.
12. Install the No.1 air cleaner hose.
1. Install the No.1 air cleaner hose with the two hose clamps (1).
2. Connect the ventilation hose with the clip (2).
13. Verify installation.
Check the installation of all parts that were replaced or removed and then reinstalled.
14. Install the No. 2 cylinder head cover.
Note
Ensure that the clips are firmly in place. Pushing in the clips with too much force or hitting the heads of the clips may damage the clip.
Snap in two clips to the back of the cover and two clips to the front of the cover to install the cylinder head cover.
15. Check for diagnostic trouble codes (DTCs).
1. Connect the Tech 2(R).
Note
If DTCs are displayed, verify the DTC and freeze frame data and record. Perform repairs as necessary.
2. Check DTCs.
16. Test drive.
Test drive the vehicle. Inspect for any problems in the warning lights, drivability, etc.