INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

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

  2. INSTALL INTAKE MANIFOLD


    1. B000NUHC01
      *a Protrusion

      Set 2 new No. 1 intake manifold to head gaskets on each cylinder head as shown in the illustration.

      Note


      • Align the port holes of the gasket, cylinder head sub-assembly and cylinder head LH.

      • Be careful of the installation direction.

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

    3. Install and uniformly tighten the 4 bolts and 4 nuts.

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

  3. INSTALL EGR VALVE ASSEMBLY

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  4. INSTALL WATER BY-PASS HOSE

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  5. CONNECT NO. 15 WATER BY-PASS HOSE

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  6. CONNECT GENERATOR CABLE AND MOTOR CABLE (for LHD)

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  7. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  8. CONNECT WIRE HARNESS

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  9. INSTALL FUEL TUBE SUB-ASSEMBLY

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  10. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  11. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    Do not apply oil to the bolts and nuts as listed below:

    Oil Application Prohibited Bolt and Nut
    Bolt and Nut for Intake Air Surge Tank Assembly and Intake Manifold
    Bolt for No. 2 Surge Tank Stay and Intake Air Surge Tank Assembly

    1. Install a new air surge tank to intake manifold gasket to the intake air surge tank assembly.

    2. Set the intake air surge tank assembly on the intake manifold.

    3. Install and uniformly tighten the 5 bolts and 2 nuts.

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

    4. Install the No. 2 surge tank stay to the intake air surge tank assembly and camshaft housing sub-assembly LH with the 2 bolts.

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

    5. Connect the PCV hose to the intake air surge tank assembly, and slide the clamp to secure the hose.

    6. Attach the 2 clamps to connect the transmission breather assembly.

    7. for RHD:

      Attach the 2 clamps to connect the motor cable and generator cable.

    8. Attach the clamp to connect the No. 1 fuel tube sub-assembly.

    9. Connect the wire harness with the bolt.

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

    10. Attach the 3 clamps.

    11. Connect the vacuum sensor connector.

    12. Connect the purge VSV to the intake air surge tank assembly with the bolt.

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

    13. Connect the No. 1 fuel vapor feed hose to the intake air surge tank assembly.

    14. Connect the purge VSV connector.

  12. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  13. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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  14. INSPECT FOR FUEL LEAK

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