Engine - Anti-Rattle Clip or Bushing Failure/Vacuum Leak

Model Sorento [BL]

Group Engine Mechanical System(12)

Number KT2008020601

Date Wednesday, February 06, 2008

Area N.America

Subject
2003-2006 Sorento Lower Induction Manifold Replacement Due to Anti-Rattle Clip or Bushing Failure/Vacuum leak

- Description

Some customer may complain of engine noise when the anti-rattle clip or throttle screws become loose and get ingested into the engine assembly causing engine noise due to the throttle shaft movement. To address these concerns, changes have been made in part configurations as well as in the part supply.

Use only the part numbers in the table below to correct the concern.

DO NOT REPLACE ENTIRE SURGE TANK (29220 39800) OR PREVIOUS ASSEMBLY (29221 39800) as charge-backs can occur.





Repair Instructions:

1. Remove the engine cover.

2. Remove the air intake hose connected to the throttle body.

3. Disconnect the throttle and cruise cables from the throttle body.

4. Remove the coolant hoses from the throttle body, plug coolant hoses to prevent coolant loss.

5. Disconnect the electrical wiring on the intake manifold.

6. Remove and plug the rubber hose from steel coolant transfer line to the coolant reservoir.

7. Remove PCV and Brake booster vacuum hose.

8. Remove the negative battery cable from the intake manifold assembly.

9. Remove the surge tank stay brackets (3).

10. Remove front and rear intake manifold studs using jam nuts to remove. This step will prevent the windshield wiper cowl and motor from having to be removed.

11. Remove surge tank and gasket.

12. Separate the surge tank from the induction manifold.

13. Remove the vacuum actuator (29223 39800) and transfer to new replacement manifold.

14. Position intake gasket P/N 29215 39800 properly and install new lower and upper manifold as an assembly. Before installing intake manifold bolts, check alignment of intake gasket to prevent vacuum leaks and excessive fuel trim concerns.

15. Install in the reverse order of removal.

16. Top-off coolant level and bleed cooling system as required.

Torque Specifications

^ Air Intake Surge Tank to Induction Valve (bolt and nut) - 11-14 ft. lbs. (14.9-18.9 Nm).

^ All stay brackets to intake manifold - 15-20 ft. lbs. (20.3-27.1 Nm).

^ Depression Chamber Body (Vacuum Valve) - 84 inch lbs. (9.4 Nm).

Use LTS for Warranty Labor Time.