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8-22Engine Lubrication
Oil Pump Overhaul (cont’d)
A
8x1.25mm
22N·m(2.2kgf·m,16lbf·ft) 8x1.25mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)A
10x1.25mm
44 N·m
(4.5 kgf·m, 33 lbf·ft)
10x1.25mm
44 N·m
(4.5 kgf·m, 33 lbf·ft) B
C
D B
A
6x1.0mm
12 N·m
(1.2 kgf·m, 8.7 lbf·ft)
3. To hold the rear balancer shaft, insert a 6 mm long pin punch (Snap-on PPC 108LA or equivalent) (A)
into the maintenance hole in the lower balancer
shaft holder and through the rear balancer shaft.
4. Apply new engine oil to the threads of the oil pump sprocket mounting bolt (A).
5. Loosely install the oil pump (B), then install the oil pump sprocket (C).
6. Tighten the oil pump mounting bolts and the oil pump sprocket mounting bolt.
7. Remove the 6 mm long pin punch (D). 8. Squeeze the new oil pump chain tensioner (A), then
install the set clip (B) on it as shown.
NOTE: The set clip is supplied with the oil pump
chain tensioner.
9. Install the new oil pump chain tensioner.
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8-23
10. Remove the set clip from the oil pump chaintensioner.
11. Install the oil pan (see page 7-29).
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Engine Mechanical
Intake Manifold and Exhaust System
.............................
.................... ................
.............
....................
Intake Manifold Removal and Installation . 9-2
Exhaust Manifold Removal and Installation . 9-11
Exhaust Pipe and Muffler Replacement . 9-13
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Exploded View - K20Z2 engine
9-2Intake Manifold and Exhaust System
Intake Manifold Removal and Installation
INTAKE AIR BYPASS (IAB)
THERMAL VALVE
JOINT GASKET
THROTTLE BODY
INTAKE MANIFOLD BRACKET
MANIFOLD
ABSOLUTE
PRESSURE
(MAP)
SENSOR INJECTOR BASE
EXHAUST GAS
PRECIRCULATION
(EGR) PLATE 6x1.0mm
12 N·m
(1.2 kgf·m, 8.7 lbf·ft)
8 x 1.25 mm
22 N·m
(2.2 kgf·m, 16 lbf·ft) 8 x 1.25 mm
22 N·m
(2.2 kgf·m,
16 lbf·ft)
GASKET
INTAKE MANIFOLD
O-RING
5x0.8mm
3.4 N·m
(0.35 kgf·m, 2.5 lbf·ft)
8x1.25mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
GASKET
8x1.25mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
GASKET
6x1.0mm
12 N·m
(1.2 kgf·m, 8.7 lbf·ft) 6x1.0mm
12 N·m
(1.2 kgf·m,
8.7 lbf·ft)
INTAKE MANIFOLD
CHAMBER
8 x 1.25 mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
GASKET
MARK
Tigten the valve to 15 N·m
(1.5 kgf·m, 11 lbf·ft), then turn the
valve joint toward the mark.
Replace.
Replace if cracked or
if mating surface is
damaged.
Replace.
Replace if cracked or
if mating surface is
damaged.
Replace.
Replace.
Replace.
Replace.
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Î
Removal - K20Z2 engine
9-3
A
B C A
B
C D
A
1. Remove the engine cover.
2. Disconnect the vacuum hose (A) and the breatherpipe (B), then remove the intake air duct (C). 3. Disconnect the engine wire harness connectors,
and remove the wire harness clamps from the
intake manifold:
Manifold absolute pressure (MAP) sensor connector
Throttle actuator connector
4. Disconnect the evaporative emission (EVAP) canister hose (A) and the brake booster vacuum
hose (B).
5. Remove the harness bracket mounting bolt (C) and the brake booster vacuum line bracket mounting
bolt (D).
6. Disconnect the water bypass hoses (A), then plug the water bypass hoses.
(cont’d)
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Installation - K20Z2 engine
9-4Intake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont’d)
A
B B
A
8x1.25mm
22 N·m
(2.2 kgf·m, 16 lbf·ft) B
A 8x1.25mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
7. Raise the vehicle on the lift to full height.
8. Remove the splash shield (see step 25 on page 5-5).
9. Remove the connector (A) from the intake manifoldbracket (B), then remove the intake manifold
bracket.
10. Lower the vehicle on the lift.
11. Remove the intake manifold. 1. Install the intake manifold (A) with a new gasket (B),
and tighten the bolts and the nuts in a crisscross
pattern in three steps, beginning with the inner bolt.
2. Raise the vehicle on the lift.
3. Install the intake manifold bracket (A), then install the connector (B) to the intake manifold bracket.
4. Install the splash shield (see step 40 on page 5-20).
5. Lower the vehicle on the lift.
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Î
9-5
A
A
B
C
6x1.0mm
12 N·m (1.2 kgf·m, 8.7 lbf·ft) D
6x1.0mm
12 N·m (1.2 kgf·m, 8.7 lbf·ft)
B
C A
6x1.0mm
12 N·m
(1.2 kgf·m, 8.7 lbf·ft)
6. Connect the water bypass hoses (A).
7. Connect the evaporative emission (EVAP) canister hose (A) and the brake booster vacuum hose (B).
8. Install the harness bracket mounting bolt (C) and the brake booster vacuum line bracket mounting
bolt (D).
9. Connect the engine wire harness connectors, and install the wire harness clamps to the intake
manifold.
Manifold absolute pressure (MAP) sensor connector
Throttle actuator connector 10. Install the intake air duct (A), then connect the
vacuum hose (B) and the breather pipe (C).
11. Install the engine cover.
12. After installation, check that all tubes, hoses and connectors are installed correctly.
13. Clean up any spilled engine coolant.
14. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater
valve open (see step 6 on page 10-8).
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