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 head sub-assembly.

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

    3. B000UA3C02
      B000XM7 Bolt
      B000TT4 Nut

      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. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 3 wire harness clamp brackets with the 4 bolts.

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

  3. 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 }

  4. INSTALL PORT FUEL INJECTOR ASSEMBLY

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  5. INSTALL INJECTOR VIBRATION INSULATOR

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  6. INSTALL NO. 1 DELIVERY PIPE SPACER

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  7. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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

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  9. INSTALL FUEL TUBE SUB-ASSEMBLY

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

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

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

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

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

  11. 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 }

  12. CONNECT PCV HOSE


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

  13. 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 the hose.

  14. CONNECT VACUUM HOSE SUB-ASSEMBLY


    1. Attach the 2 clamps and connect the vacuum hose sub-assembly to the intake air surge tank assembly.

  15. CONNECT NO. 5 ENGINE WIRE


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

  16. CONNECT ENGINE WIRE


    1. Connect the 7 connectors.

    2. Attach the 6 clamps.

    3. Install the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. B000VBQC04
      *a Bolt (A)
      *b Bolt (B)
      B000XM7 Bolt
      B000TT4 Connector
      B000YI8 Nut

      Connect the 5 connectors.

    5. Attach the 4 clamps.

    6. Install the bolt (A), (B) and nut.

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

    7. Attach the fuel tube sub-assembly to the engine wire.

    8. Connect the 17 connectors.

    9. Attach the 4 clamps.

    10. Install the 2 bolts and 4 nuts.

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

  17. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

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  18. INSTALL INJECTOR DRIVER

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  19. INSTALL PURGE VSV

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  20. INSTALL AIR CLEANER HOSE CLAMP


    1. Attach the clamp and install the air cleaner hose clamp.

  21. INSTALL NO. 2 INTAKE AIR CONNECTOR PIPE


    1. Install the No. 2 intake air connector pipe to the No. 3 intake air connector pipe, and slide the clamp to secure the hose.

    2. Install a blot.

      Torque:
      5.0 N*m  { 51 kgf*cm, 4 ft.*lbf }

    3. Attach the air cleaner hose clamp.

  22. INSTALL INTAKE AIR SOUND CREATOR


    1. Install the intake air sound creator with the 2 bolts and hose clamp.

      Torque:
      for bolt
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      for hose clamp
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  23. INSTALL INTAKE AIR CONNECTOR PIPE


    1. Install the intake air connector pipe with the bolt and hose clamp.

      Torque:
      for bolt
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      for hose clamp
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  24. INSTALL AIR CLEANER WITH ELEMENT ASSEMBLY LH

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  25. INSTALL AIR CLEANER WITH ELEMENT ASSEMBLY RH

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  26. INSTALL RADIATOR SUPPORT TO CROSS MEMBER BRACE SUB-ASSEMBLY RH

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  27. INSTALL RADIATOR SUPPORT TO CROSS MEMBER BRACE SUB-ASSEMBLY LH

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  28. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  30. INSPECT FOR FUEL LEAK

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