INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL INTAKE MANIFOLD


    1. Set 2 new gaskets on each cylinder head sub-assembly.

      Note


      • Align the port holes of the gaskets and cylinder head sub-assembly.

      • Make sure that the gaskets are installed in the correct direction.

    2. Set the intake manifold on the cylinder head sub-assembly.

    3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.

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

  2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    Click here

  3. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  4. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side)

    Click here

  5. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting Stay Side)

    Click here

  6. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    Do not apply oil to the bolts listed below:

    Oil Application Prohibited Bolt
    Bolt for Intake Air Surge Tank Assembly and Intake Manifold
    Bolt for No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    Bolt for Throttle Body Bracket and Intake Air Surge Tank Assembly

    1. Install 3 new gaskets to the intake air surge tank assembly.

    2. Temporarily install the intake air surge tank assembly with the 4 bolts and 2 nuts.

    3. A01W4PBE02

      Using a 5 mm hexagon socket wrench, in several steps, uniformly tighten the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      Bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Install the No. 1 surge tank stay to the intake air surge tank assembly with the bolt.

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

    5. Install the throttle body bracket to the intake air surge tank assembly with the bolt.

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

    6. Install the vacuum hose clamp to the throttle body bracket with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      Install the vacuum hose clamp so that its tab is in contact with the No. 1 surge tank stay.

    7. Connect the intake air control valve assembly connector.

    8. Connect the fuel vapor feed hose to the intake air surge tank assembly.

    9. Connect the 2 water by-pass hoses to the throttle body assembly and slide the 2 clips to secure them.

    10. Connect the throttle body assembly connector.

    11. Engage the wire harness clamp.

    12. for LHD:


      1. Engage the hose clamp.

      2. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.

    13. for RHD:


      1. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.

    14. Connect the ventilation hose to the intake air surge tank assembly and slide the clip to secure it.

  7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  8. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  9. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  10. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  12. ADD ENGINE COOLANT

    Click here

  13. INSPECT FOR COOLANT LEAK

    Click here

  14. INSPECT FOR FUEL LEAK

    Click here

  15. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here