DIESEL THROTTLE BODY INSTALLATION

CAUTION / NOTICE / HINT

Note

Disconnect the cable from the negative (-) battery terminal to clear the diesel throttle valve fully closed position learned value.

PROCEDURE


  1. INSTALL DIESEL THROTTLE BODY ASSEMBLY LH


    1. Install a new gasket to the intake pipe.

    2. B001ZYU

      Install the throttle body with the 2 bolts and 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Connect the throttle position sensor connector.

    4. Connect the throttle motor connector.

  2. INSTALL DIESEL THROTTLE BODY ASSEMBLY RH


    1. Install a new gasket to the intake pipe.

    2. B001WLR

      Install the throttle body with the 2 bolts and 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Connect the throttle position sensor connector.

    4. Connect the throttle motor connector.

  3. INSTALL TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)


    1. B00202H

      Temporarily install the flare nut of the tube connector to flexible hose tube to the clutch tube to release cylinder 2 way by hand.

    2. B001Y6QE02

      Temporarily install the tube connector to flexible hose tube with the 2 bolts.

    3. Tighten the bolt labeled A.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Tighten the bolt labeled B after installing the clutch hose.

  4. INSTALL AIR TUBE SUB-ASSEMBLY LH

    B001Z95E03
    *1 Embossed Mark
    *2 Upper
    *3 Front
    *4 Paint Mark

    1. Install the air tube to the throttle body.

    2. Align the embossed mark of the throttle body with the paint mark of the No. 4 air hose.

    3. B001VO9E01
      *1 7 to 11 mm

      Tighten the hose clamp so that it is 7 to 11 mm (0.276 to 0.433 in.) from the end of the hose as shown in the illustration.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  5. INSTALL CLUTCH HOSE (for Manual Transmission)


    1. B001Z8BE02

      Connect the clutch hose to the air tube with the bolt labeled A.

    2. Temporarily install the clutch hose to the clutch master cylinder tube to flexible hose tube and tube connector to flexible hose tube, and fix it in place with the 2 clips.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Tighten the bolt labeled B.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Tighten the flexible hose tube.

      Note


      • Do not bend or damage the flexible hose tube.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting points.

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). If using a torque wrench with a length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure union nut wrench and the wrench are connected in a straight line.


      1. B001X3ZE02
        *1 Fulcrum Length

        Using a 10 mm union nut wrench, tighten the 2 flare nuts of the flexible hose tube.

        Torque:
        without union nut wrench
        15 N*m  { 154 kgf*cm, 11 ft.*lbf }
        with union nut wrench
        14 N*m  { 141 kgf*cm, 10 ft.*lbf }
      2. B001WYSE02
        *1 Fulcrum Length

        Using a 10 mm union nut wrench, tighten the flare nut of the flexible hose tube.

        Torque:
        without union nut wrench
        15 N*m  { 154 kgf*cm, 11 ft.*lbf }
        with union nut wrench
        14 N*m  { 141 kgf*cm, 10 ft.*lbf }

  6. INSTALL AIR TUBE SUB-ASSEMBLY RH

    B00203YE03
    *1 Embossed Mark
    *2 Upper
    *3 Front
    *4 Paint Mark

    1. Install the air tube to the throttle body.

    2. Align the embossed mark of the throttle body with the paint mark of the No. 4 air hose.

    3. B001VO9E01
      *1 7 to 11 mm

      Tighten the hose clamp so that it is 7 to 11 mm (0.276 to 0.433 in.) from the end of the hose as shown in the illustration.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  7. CONNECT NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B001Y6G

      Connect the dipstick guide with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  8. INSTALL NO. 1 COOL AIR INLET (w/o Intercooler)

    Click here

  9. INSTALL NO. 2 COOL AIR INLET (w/o Intercooler)

    Click here

  10. INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)


    1. Click here

  11. FILL BRAKE FLUID RESERVOIR

    Click here

  12. BLEED CLUTCH LINE

    Click here

  13. CHECK FLUID LEVEL IN RESERVOIR

    Click here

  14. INSPECT FOR CLUTCH FLUID LEAK

  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  16. CHECK DIESEL THROTTLE BODY ASSEMBLY

    Click here

  17. PERFORM DIESEL THROTTLE BODY INITIALIZATION

    Click here