Removal and installation
Before you start removing parts, do the following:
- A) (GDI engines) Remove the decorative engine cover.
- b) Remove the engine crankcase guard.
Removal of parts is carried out in the order of the numbers indicated in the figure "Removing the exhaust manifold".
Removing the exhaust manifold (engine 4G15-GDI). 1 - exhaust pipe, 2 - exhaust pipe gasket, 3 - engine suspension bracket, 4 - guide tube and engine oil level dipstick assembly, 5 - ring gasket, 6 - switch connector for fluid pressure in the booster hydraulic system steering, 7 - air conditioning compressor magnetic clutch connector, 8 - air conditioning compressor and power steering pump drive belt, 9 - power steering pump and adjusting bar assembly, 10 - oxygen sensor, 11 - heat shield, 12 - exhaust manifold bracket, 13 - exhaust manifold, 14 - exhaust manifold gasket.
Removing the exhaust manifold (engine 4G93-GDI). 1 - exhaust pipe, 2 - exhaust pipe gasket, 3 - guide tube and engine oil level dipstick assembly, 4 - oxygen sensor, 5 - heat shield, 6 - bracket "IN" exhaust manifold, 7 - exhaust manifold, 8 - exhaust manifold gasket, 9 - bracket "A" exhaust manifold.
Removing the exhaust manifold (4G15-MPI engine). 1 - exhaust pipe, 2 - exhaust pipe gasket, 3 - guide tube and engine oil level dipstick assembly, 4 - O-ring, 5 - oxygen sensor, 6 - heat shield, 7 - bracket "IN" exhaust manifold, 8 - exhaust manifold, 9 - exhaust manifold gasket, 10 - bracket "A" exhaust manifold.
Removing the exhaust manifold (engine 4G93-MPI).1 - power steering pump strut mounting bolt, 2 - air conditioning compressor and power steering pump drive belt, 3 - tensioner bracket and power steering pump assembly, 4 - exhaust pipe, 5 - exhaust pipe gasket, 6 - bracket "IN" exhaust manifold, 7 - oxygen sensor, 8 heat shield, 9 - exhaust manifold, 10 - exhaust manifold gasket, 11 - bracket "A" exhaust manifold.
When removing parts, pay attention to the operation
1. (Engine 4G15-GDI) Removing the power steering pump drive belt.
A) Loosen the bolts "A", "IN" And "WITH" power steering pump.
b) Loosen the adjusting bolt "D" to relieve belt tension, then remove the belt.
Attention: in case of reusing the drive belt for the air conditioning compressor and power steering pump, it is necessary to chalk on the back (non-working) belt surface an arrow indicating the direction of rotation (clockwise).
2. (Engine 4G15-GDI) Removing the power steering pump and adjusting bar assembly.
Remove the power steering pump and adjuster bar assembly with connected hoses.
Note: after removal, secure the power steering pump with hoses with wire in a place where it will not be obstructed or damaged.
3. (Engine 4G93-MPI) Remove tensioner bracket and power steering pump assembly.
Remove the tensioner bracket and power steering pump assembly along with the connected hoses.
Note: after removal, secure the power steering pump with hoses with wire in a place where it will not be obstructed or damaged.
4. Removing the oxygen sensor.
To avoid damage to the sensor wiring, use a special tool head to remove it.
− Installation of parts is carried out in the reverse order of removal.
When installing the parts, pay attention to the installation operation of the oxygen sensor.
To avoid damage to the sensor wiring, use a special tool head to install it.
− After completing the installation of the parts, perform the following operations:
- A) Install the engine crankcase guard.
- b) (GDI engines) Install the decorative engine cover.
Examination
1. Check the exhaust manifold and heat shield for damage.
2. Check for exhaust manifold leaks (due to burning) and connections to the downpipe of the exhaust system.
3. Using a ruler and a set of probes, measure the non-flatness of the mating surface of the cylinder head, as well as the mating surface of the exhaust manifold.
Non-flatness of the mating surface:
- Nominal - 0.15 mm or less
- Maximum allowable - 0.20 mm
4. If defects are found during the inspection of the above points, the part must be replaced.