INTAKE MANIFOLD INSTALLATION

Info Added 2017-10-06

PROCEDURE


  1. INSTALL STUD BOLT (w/ Stud Bolt)

    Tech Tips

    If a stud bolt is deformed or the threads are damaged, replace it.


    1. A001P2Z

      Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  2. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET


    1. Install a new No. 1 intake manifold to head gasket to the intake manifold.

  3. INSTALL INTAKE MANIFOLD


    1. Temporarily install the intake manifold to the cylinder head sub-assembly with the 3 bolts and 2 nuts.

    2. A001Q9JC01
      B0048I2 Bolt
      B0048S8 Nut

      Tighten the 3 bolts and 2 nuts in several steps.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  4. CONNECT WATER BY-PASS HOSE


    1. A001QEMC01
      *1 Water By-Pass Hose
      *2 No. 2 Water By-pass Hose

      Engage the 2 hose clamps to connect the No. 2 water by-pass hose to the intake manifold.

    2. Engage the 2 hose clamps to connect the water by-pass hose to the intake manifold.

  5. CONNECT NO. 2 FUEL VAPOR FEED HOSE


    1. Connect the No. 2 fuel vapor feed hose to the intake manifold.

    2. Engage the 2 hose clamps to connect the No. 2 fuel vapor feed hose to the intake manifold.

  6. CONNECT NO. 8 WATER BY-PASS HOSE


    1. Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.

    2. Engage the 2 hose clamps.

  7. CONNECT ENGINE COVER BRACKET


    1. Connect the engine cover bracket to the intake manifold with the bolt.

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

  8. CONNECT ENGINE WIRE


    1. A001PMO

      Engage the clamp and connect the engine wire with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 4 fuel injector assembly connectors and purge valve (purge VSV) connector.

    3. A001RYJ

      Connect the wire harness bracket with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    4. A001PVE

      Connect the engine water pump assembly connector.

    5. Engage the 2 clamps.

  9. CONNECT VENTILATION HOSE


    1. Connect the ventilation hose to the intake manifold and slide the clip to secure it.

  10. INSTALL E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)


    1. Install the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) to the intake manifold with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the vacuum hose to the intake manifold.

    3. Connect the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) connector.

  11. INSTALL EGR PIPE ASSEMBLY


    1. A001QSPC01
      *a Claw

      Install a new EGR pipe gasket to the EGR valve assembly.

      Note

      Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

    2. A001RZGC01
      *a Groove
      *b Protrusion

      Install a new inlet EGR gasket to the intake manifold.

      Tech Tips

      Align the protrusion of the inlet EGR gasket with the groove of the intake manifold.

    3. Install the EGR pipe assembly to the intake manifold and EGR valve assembly with the 4 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  12. INSTALL NO. 1 AIR CLEANER INLET


    1. Install the No. 1 air cleaner inlet to the intake manifold with the 2 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  13. INSTALL AIR CLEANER BRACKET


    1. A001QEPC02
      *a Bolt (A)
      *b Bolt (B)

      Engage the wire harness clamp and install the air cleaner bracket to the cylinder block sub-assembly and air conditioning wire with the bolt (A) and 2 bolts (B).

      Torque:
      Bolt (A)
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }
      Bolt (B)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  14. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case sub-assembly to the air cleaner bracket with the 2 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  15. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

  16. INSTALL NO. 2 AIR CLEANER INLET


    1. A001PATC01
      *a Groove
      *b Protrusion

      Temporarily install the No. 2 air cleaner inlet to the No. 1 air cleaner inlet and upper radiator support sub-assembly with the 2 bolts.

      Tech Tips

      Align the protrusion of the No. 1 air cleaner inlet with the groove of the No. 2 air cleaner inlet.

    2. Tighten the 2 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Tighten the hose clamp.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  17. INSTALL RADIATOR COVER

    Click here

  18. INSTALL THROTTLE BODY ASSEMBLY

    Click here

  19. INSPECT INTAKE SYSTEM

    Tech Tips

    Perform Inspection After Repair after repairing any vacuum leaks in the intake system.

    Click here