RM38T0EC _51 Engine / Hybrid System _144997 M20F-FXS, M20G-FXS INTAKE / EXHAUST _0604322 INTAKE MANIFOLD A

M20F-FXS, M20G-FXS INTAKE / EXHAUST INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

2.385,1.021 2.896,1.021 false 5.698,1.917 5.865,1.917 5.865,1.917 6.167,1.688 false 4.188,1.5 3.948,1.896 3.948,1.896 3.708,1.896 false 3.813,2.854 4.458,2.854 false 5.302,2.833 5.698,2.833 false 4.771,2.531 5.156,2.531 false 1.146,3.677 1.573,3.677 false 1.188,0.271 1.698,0.271 false 6.177,2.354 6.51,2.354 false 1.615,4.51 1.615,4.094 false 1.51,5.125 1.708,5.125 1.708,5.125 2.052,5.438 false 1.271,5.615 1.5,5.615 false 2.823,3.969 3.219,3.406 3.219,3.406 3.427,3.406 false 4.896,1.76 4.896,1.458 false 0.938,4.531 0.938,4.323 false 3.333,5.344 3.563,4.802 3.563,4.802 3.771,4.802 false 2.177,0.896 2.573,1.271 0.396,0.375 18 false 1 5.531,1.792 5.927,2.167 0.396,0.375 18 false 2 4.854,1.823 5.25,2.198 0.396,0.375 18 false 3 3.375,1.76 3.771,2.135 0.396,0.375 18 false 4 3.604,2.729 4,3.104 0.396,0.375 18 false 5 5.948,2.708 6.344,3.083 0.396,0.375 18 false 6 5.406,2.406 5.802,2.792 0.396,0.385 18 false 7 0.969,3.563 1.365,3.938 0.396,0.375 18 false 8 1.333,4.99 1.729,5.365 0.396,0.375 18 false 9 1.75,0.125 2.146,0.5 0.396,0.375 18 false 10 0.865,4.573 1.26,4.948 0.396,0.375 18 false 11 4.063,4.708 4.458,5.083 0.396,0.375 18 false 12 3.458,3.25 3.854,3.625 0.396,0.375 18 false 13 6.719,2.219 7.115,2.594 0.396,0.375 18 false 14 1.458,4.521 1.854,4.896 0.396,0.375 18 false 15 1.552,5.5 1.958,5.802 0.406,0.302 18 false 10 2.24,3.052 2.635,3.427 0.396,0.375 10 false x2 3.417,3.583 3.813,3.958 0.396,0.375 10 false x4 3.99,2.188 4.385,2.563 0.396,0.375 10 false x4 0.323,0.76 0.719,1.135 0.396,0.375 10 false x2 5.792,2.74 6.188,3.115 0.396,0.375 10 false ● 5.26,2.438 5.656,2.813 0.396,0.375 10 false ● 3.573,1.813 3.969,2.188 0.396,0.375 10 false ● 6.583,2.26 6.979,2.635 0.396,0.375 10 false ● 3.344,0.844 3.74,1.219 0.396,0.375 10 false x3 5.333,0.302 5.729,0.677 0.396,0.375 10 false x3

Procedure		Part Name Code
1	INLET NO. 1 AIR CLEANER	17751	-	-	-
2	AIR CLEANER CAP WITH AIR CLEANER HOSE	-	-	-	-
3	THROTTLE BODY WITH MOTOR ASSEMBLY	22030	(202307,999999,_51,_144997,_0604322,RM100000002BTVQ_01_0134,)	-	-
4	THROTTLE BODY GASKET	22271	-	-	-
5	NO. 1 EGR PIPE SUB-ASSEMBLY	25601	(202307,999999,_51,_144997,_0604322,RM100000002BTVQ_01_0171,)	-	-
6	EGR VALVE ADAPTER GASKET	25629	-	-	-
7	EGR INLET GASKET	25628	-	-	-
8	E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)	89421	-	-	-
9	NO. 1 FUEL VAPOR FEED HOSE	23826	-	-	-
10	ENGINE WIRE	82121	-	-	-
11	NO. 2 WATER BY-PASS PIPE	16278	(202307,999999,_51,_144997,_0604322,RM100000002BTVQ_01_0183,)	-	-
12	INTAKE MANIFOLD STAY	17138B	(202307,999999,_51,_144997,_0604322,RM100000002BTVQ_01_0178,)	-	-
13	INTAKE MANIFOLD	17111	-	-	-
14	NO. 1 INTAKE MANIFOLD TO HEAD GASKET	17177	-	-	-
15	VACUUM HOSE	-	-	-	-

●

Non-reusable part

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during intake manifold removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
· Replacement of throttle body with motor assembly · Cleaning the deposits from the throttle body with motor assembly · Gas leak from exhaust system is repaired	Inspection After Repair	· Poor idle, etc. · Engine start function, etc.	(202307,999999,_51,_144956,_0604911,RM100000002BWPD,)

CAUTION:: ·

·

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>PRECAUTION202307,999999,_51,_144957,_0604232,RM100000002BTK4,

·

To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

NOTICE:: ·

After the power switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Audio and Visual System (for HV Model))

·

After the power switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Navigation System (for HV Model))

·

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION202307,999999,_V1,_107171,_0486700,RM100000002CS4V,

NOTICE:: ·

After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal. (w/ Radio and Display Receiver assembly)

·

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION202307,999999,_V1,_107171,_0486700,RM100000002CS4V,

PROCEDURE

Hide Display 17751 1.REMOVE INLET NO. 1 AIR CLEANER

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (COOLING)>RADIATOR>REMOVAL202307,999999,_51,_144716,_0603000,RM100000002BNMC_01_0180,

Hide Display 2.REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>THROTTLE BODY>REMOVAL202307,999999,_51,_144956,_0604219,RM100000002BTIE_01_0025,

Hide Display 22030 3.SEPARATE THROTTLE BODY WITH MOTOR ASSEMBLY

2.521,1.469 2.656,1.76 0.135,0.292 18 true i 3.906,0.021 4.094,0.302 0.188,0.281 18 true ii

Disconnect the throttle body with motor assembly connector.

ii.

Using an 8 mm socket wrench, remove the 3 bolts to separate the throttle body with motor assembly from the intake manifold.

Hide Display 22271 4.REMOVE THROTTLE BODY GASKET

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>THROTTLE BODY>REMOVAL202307,999999,_51,_144956,_0604219,RM100000002BTIE_01_0027,

Hide Display 25601 5.REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (EMISSION CONTROL)>EGR VALVE>REMOVAL202307,999999,_51,_144996,_0604305,RM100000002BTUJ_01_0044,

Hide Display 25629 6.REMOVE EGR VALVE ADAPTER GASKET

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (EMISSION CONTROL)>EGR VALVE>REMOVAL202307,999999,_51,_144996,_0604305,RM100000002BTUJ_01_0043,

Hide Display 25628 7.REMOVE EGR INLET GASKET

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (EMISSION CONTROL)>EGR VALVE>REMOVAL202307,999999,_51,_144996,_0604305,RM100000002BTUJ_01_0042,

Hide Display 89421 8.REMOVE E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (EMISSION CONTROL)>VACUUM SENSOR>REMOVAL202307,999999,_51,_144996,_0604307,RM100000002BTUN,

Hide Display 23826 9.REMOVE NO. 1 FUEL VAPOR FEED HOSE

Hide Display 82121 10.DISCONNECT ENGINE WIRE

Hide Display 16278 11.DISCONNECT NO. 2 WATER BY-PASS PIPE

0.552,0.156 0.833,0.51 0.281,0.354 18 false i

Using an 8 mm socket wrench, remove the bolt and separate the No. 2 water by-pass pipe from the intake manifold.

Hide Display 17138B 12.REMOVE INTAKE MANIFOLD STAY

3.104,1.146 3.292,1.458 0.188,0.313 18 true i 4.531,0.438 4.729,0.74 0.198,0.302 18 true ii 2.531,0.677 2.771,0.979 0.24,0.302 18 true iii 3.354,1.156 3.583,1.396 0.229,0.24 12 true A 4.208,0.469 4.438,0.708 0.229,0.24 12 true B

Using an 8 mm socket wrench, remove the bolt (A).

ii.

Remove the bolt (B).

iii.

Disengage the guide and remove the intake manifold stay.

Hide Display 17111 13.REMOVE INTAKE MANIFOLD

Hide Display 17177 14.REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Hide Display 15.REMOVE VACUUM HOSE