INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL INTAKE AIR SURGE TANK ASSEMBLY


    1. Install 2 new No. 1 intake manifold to head gaskets to the cylinder block sub-assembly.

    2. Temporarily install the intake air surge tank assembly to the cylinder block sub-assembly with the 8 bolts and 2 nuts.

    3. B002DMQN01

      Tighten the 8 bolts and 2 nuts in the order shown in the illustration.

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

    4. Connect the wire harness bracket to the intake air surge tank assembly with the bolt.

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

  2. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. Connect the No. 1 fuel pipe sub-assembly to the intake air surge tank assembly with the bolt.

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

  3. INSTALL NO. 2 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. Install the No. 2 V-bank cover bracket sub-assembly to the intake air surge tank assembly with the bolt.

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

  4. INSTALL V-BANK COVER BRACKET SUB-ASSEMBLY


    1. Install the V-bank cover bracket sub-assembly to the intake air surge tank assembly with the bolt.

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

  5. INSTALL PORT FUEL INJECTOR ASSEMBLY

    Click here

  6. INSTALL INJECTOR VIBRATION INSULATOR

    Click here

  7. INSTALL NO. 1 DELIVERY PIPE SPACER

    Click here

  8. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    Click here

  9. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

    Click here

  10. INSTALL FUEL TUBE SUB-ASSEMBLY

    Click here

  11. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the water by-pass pipe sub-assembly to the intake air surge tank assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. B002CQ2C01
      *1 Heater Water Inlet Hose
      *2 Heater Water Outlet Hose
      *3 No. 3 Water By-pass Hose
      *4 Water By-pass Hose
      *5 No. 5 Water By-pass Hose

      Connect the heater water inlet hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    3. Connect the heater water outlet hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    4. Connect the No. 5 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    5. Connect the water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    6. Connect the No. 3 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

  12. INSTALL INJECTOR DRIVER BRACKET


    1. Install the 2 injector driver brackets to the intake air surge tank assembly with the 4 bolts.

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

  13. CONNECT VENTILATION HOSE


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

  14. INSTALL FUEL VAPOR FEED HOSE


    1. Install the fuel vapor feed hose to the intake air surge tank assembly and slide the clip to secure it.

  15. CONNECT VACUUM HOSE SUB-ASSEMBLY


    1. Connect the vacuum hose sub-assembly to the intake air surge tank assembly.

  16. CONNECT NO. 5 ENGINE WIRE


    1. Engage the 4 clamps and connect the No. 5 engine wire to the intake air surge tank assembly.

  17. ENGAGE ENGINE WIRE


    1. Engage the wire harness to the engine room ECU box.

      Click here

    2. Connect the engine wire harness connector.

    3. Engage the claw and connect the engine wire harness.

    4. B002EFIC02
      B002DP3 Bolt
      B002CU5 Connector

      Connect the 7 connectors.

    5. Engage the 7 clamps.

    6. Install the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    7. B002CRDC01
      *a Bolt (A)
      *b Bolt (B)
      B002DP3 Bolt
      B002CU5 Connector

      Connect the 4 connectors.

    8. Engage the 2 clamps.

    9. Install the bolt (A) and (B).

      Torque:
      Bolt (A)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt (B)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    10. for LHD:


      1. Engage the fuel tube sub-assembly to the engine wire.

        B002DQHC01
        B002DP3 Bolt B002CU5 Nut
        B002CVE Connector B002DL3 Fuel Tube Sub-assembly

      2. Connect the 12 connectors.

      3. Engage the 4 clamps.

      4. Install the 2 bolts and 4 nuts.

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

    11. for RHD:


      1. Engage the fuel tube sub-assembly to the engine wire.

        B002F1GC01
        B002DP3 Bolt B002CU5 Nut
        B002CVE Connector B002DL3 Fuel Tube Sub-assembly

      2. Connect the 12 connectors.

      3. Engage the 5 clamps.

      4. Install the 2 bolts and 4 nuts.

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

  18. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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  19. INSTALL ENGINE ROOM ECU COVER

    Click here

  20. CONNECT UNION TO CHECK VALVE HOSE


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

  21. INSTALL INJECTOR DRIVER

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  22. INSTALL PURGE VALVE (PURGE VSV)

    Click here

  23. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

    Note

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

    Click here

  25. INSPECT FOR FUEL LEAK

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