Removal and Replacement

Starter:

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DRAIN ENGINE COOLANT
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. REMOVE INTAKE AIR CONNECTOR
6. DISCONNECT FUEL HOSE
7. DISCONNECT NO. 2 FUEL HOSE
8. REMOVE VENTILATION HOSE
9. REMOVE PURGE VSV
10. REMOVE VACUUM CONTROL VALVE SET
11. DISCONNECT ENGINE WIRE
a. Disconnect the 8 fuel injector connectors.
b. Disconnect the throttle position sensor and control motor connector.
c. Disconnect the engine coolant temperature sensor connector.
d. Remove the 3 bolts and disconnect the engine wire.

12. DISCONNECT NO. 7 WATER BY-PASS HOSE

13. DISCONNECT WATER BY-PASS HOSE
14. REMOVE INTAKE MANIFOLD ASSEMBLY
a. Remove the 6 bolts and 4 nuts.
b. Remove the intake manifold and 2 gaskets.

15. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Disconnect the No. 2 engine wire.
b. Remove the nut and water by-pass pipe.

16. REMOVE REAR WATER BY-PASS JOINT
a. Remove the 4 nuts, water by-pass joint and 2 gaskets.

17. REMOVE AIR PUMP ASSEMBLY WITH BRACKET
18. REMOVE AIR SWITCHING VALVE ASSEMBLY
19. REMOVE STARTER ASSEMBLY

a. Disconnect the starter connector.
b. Remove the nut and disconnect the starter cable.
c. Remove the bolt and disconnect the engine wire protector.
d. Remove the 2 bolts and starter.

INSTALLATION

1. INSTALL STARTER ASSEMBLY

a. Install the starter with the 2 bolts.

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

b. Connect the engine wire protector with the bolt.
c. Connect the starter cable with the nut.

Torque: 9.8 N.m (100 kgf.cm, 86 in.lbf)

d. Connect the starter connector.

2. INSTALL AIR SWITCHING VALVE ASSEMBLY
3. INSTALL AIR PUMP ASSEMBLY WITH BRACKET
4. INSTALL REAR WATER BY-PASS JOINT
a. Install 2 new gaskets to the cylinder head.
b. Install the 4 nuts holding the water by-pass joint to the cylinder heads. Alternately tighten the nuts.

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

5. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring.
c. Push the water by-pass pipe end into the pipe hole of the water pump.
d. Install the water by-pass pipe with the nut.

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

e. Install the wire clamp to the bracket of the water bypass pipe.

6. INSTALL INTAKE MANIFOLD ASSEMBLY
a. Install 2 new gaskets to the cylinder head.
b. Install the intake manifold with the 4 bolts and 2 nuts.

Torque:
18 N.m (185 kgf.cm, 13 ft.lbf) for bolt
18 Nm (185 kgf.cm, 13 ft.lbf) for nut

7. CONNECT WATER BY-PASS HOSE
8. CONNECT NO. 7 WATER BY-PASS HOSE

9. INSTALL ENGINE WIRE
a. Install the 3 bolts and connect the engine wire.

Torque: 8.2 N.m (83 kgf.cm, 72 in.lbf)

b. Connect the engine coolant temperature sensor connector.
c. Connect the throttle position sensor and control motor connector.
d. Connect the 8 fuel injector connectors.

10. INSTALL VACUUM CONTROL VALVE SET
11. INSTALL PURGE VSV
12. CONNECT VENTILATION HOSE
13. CONNECT NO. 2 FUEL HOSE
14. CONNECT FUEL HOSE
15. INSTALL INTAKE AIR CONNECTOR
16. ADD ENGINE COOLANT
17. CHECK FOR ENGINE COOLANT LEAKS
a. Check for engine coolant leaks.

18. CHECK FOR FUEL LEAKS
19. INSTALL V-BANK COVER SUB-ASSEMBLY
20. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting the cable from the negative (-) battery terminal.