INTAKE MANIFOLD

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INSTALL INTAKE MANIFOLD
1. Install 2 new gaskets to the intake manifold.
2. Temporarily Install the intake manifold with the 8 bolts and 2 nuts.
3. Uniformly tighten the bolts and nuts in the order shown in the illustration.
  
  21 N*m 214 kgf*cm 15 ft.*lbf
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CONNECT PCV HOSE
1. Connect the PCV hose to the intake manifold.
  
  Tip:
  Make sure the direction of the hose clamp is as shown in the illustration.
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INSTALL PURGE VSV
1. Install the purge VSV with the bolt.
  
  21 N*m 214 kgf*cm 15 ft.*lbf
2. Connect the 2 purge line hoses.
  
  Tip:
  Make sure the direction of the hose clamp is as shown in the illustration.
3. Connect the purge VSV connector.
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INSTALL WATER BY-PASS PIPE HOSE
1. Install the water by-pass pipe hose with the 2 bolts.
  
  10 N*m 102 kgf*cm 7 ft.*lbf
2. Connect the 4 water hoses.
  
  Tip:
  Make sure the direction of the hose clamp is as shown in the illustration.
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INSTALL NO. 3 ENGINE COVER SUB-ASSEMBLY
1. Install the No. 3 cover sub-assembly with the 2 clips.
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INSTALL ENGINE MOTOR CABLE CLAMP BRACKET (for LHD)
1. Install the engine motor cable clamp bracket with the bolt.
  
  10 N*m 102 kgf*cm 7 ft.*lbf
2. Connect the wire harness clamp to the motor cable clamp bracket.
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INSTALL FLEXIBLE HOSE BRACKET SUB-ASSEMBLY (for LHD)
1. Install the flexible hose bracket sub-assembly with the bolt.
  
  8.0 N*m 82 kgf*cm 71 in.*lbf
2. Connect the flexible hose to the bracket.
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INSTALL NO. 2 ENGINE MOTOR CABLE CLAMP BRACKET (for RHD)
1. Install the No. 2 engine motor cable bracket with the bolt.
  
  10 N*m 102 kgf*cm 7 ft.*lbf
2. Attach the 2 wire harness clamps to the bracket.
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INSTALL NO. 1 ENGINE MOTOR CABLE CLAMP BRACKET (for RHD)
1. Install the No. 1 engine motor cable clamp bracket with the bolt to the No. 2 engine motor cable bracket.
  
  8.0 N*m 82 kgf*cm 71 in.*lbf
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CONNECT GENERATOR CABLE (for RHD)
1. Connect the generator cable with the 2 clamps.
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CONNECT MOTOR CABLE (for RHD)
1. Connect the motor cable with the clamp.
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INSTALL INJECTOR DRIVER
1. Install the No. 1 engine cover to the intake manifold.
2. Install the injector driver with the 2 bolts and 2 nuts.
3. Uniformly tighten the bolts and nuts in the order shown in the illustration.
  
  10 N*m 102 kgf*cm 7 ft.*lbf
4. Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as shown in the illustration to lock the connectors.
5. Connect the 3 wire harness claws to the bracket.

CONNECT ENGINE WIRE HARNESS (for LHD)

Connect the engine wire harness protector to the intake manifold with the 4 nuts.

10 N*m 102 kgf*cm 7 ft.*lbf
Connect the 3 wire harness brackets with the 3 bolts.

10 N*m 102 kgf*cm 7 ft.*lbf

Connect the 4 ground cables with the 4 bolts.

for timing chain cover
10 N*m	102 kgf*cm	7 ft.*lbf
for engine room RH side
8.5 N*m	87 kgf*cm	75 in.*lbf

Connect the 3 engine wire harness clamps labeled B.
Attach the 4 engine wire harness clamps labeled A.
Connect the engine wire harness connectors.

Tip:
Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as shown in the illustration to lock the connectors.

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CONNECT ENGINE WIRE HARNESS (for RHD)

Connect the engine wire harness protector to the intake manifold with the 4 nuts.

10 N*m 102 kgf*cm 7 ft.*lbf
Connect the 4 wire harness brackets with the 4 bolts.

10 N*m 102 kgf*cm 7 ft.*lbf

Connect the 4 ground cables with the 4 bolts.

for timing chain cover
10 N*m	102 kgf*cm	7 ft.*lbf
for engine room RH side
8.5 N*m	87 kgf*cm	75 in.*lbf

Connect the 3 engine wire harness clamps labeled B.
Attach the 4 engine wire harness clamps labeled A.
Connect the engine wire harness connectors.

Tip:
Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as shown in the illustration to lock the connectors.

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CONNECT ECM CONNECTOR
1. Connect the engine wire harness to the ECM box and connect the 4 ECM connectors.
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CONNECT NO. 2 CONNECTOR HOLDER
1. Attach the No. 2 connector holder.
2. Attach the wire harness clamp A to the ECM box.
3. Connect the 3 connectors.
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CONNECT HYBRID VEHICLE CONTROL ECU CONNECTOR
1. Connect the connector to the hybrid vehicle control ECU.
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INSTALL OUTLET ENGINE ROOM ECM DUCT
1. Install the outlet engine room ECM duct.
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INSTALL ENGINE ROOM ECU COVER
1. Install the engine room ECU cover with the 3 bolts.
  
  5.5 N*m 56 kgf*cm 49 in.*lbf
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INSTALL NO. 6 COVER SUB-ASSEMBLY (for LHD)
1. Install the No. 6 cover sub-assembly.
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INSTALL ENGINE COVER SUB-ASSEMBLY LH (for LHD)
1. Install the engine cover sub-assembly LH with the 4 nuts.
  
  21 N*m 214 kgf*cm 15 ft.*lbf
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INSTALL NO. 5 COVER SUB-ASSEMBLY (for RHD)
1. Install the No. 5 cover sub-assembly.
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INSTALL ENGINE COVER SUB-ASSEMBLY RH (for RHD)
1. Install the engine cover sub-assembly RH with the 4 nuts.
  
  21 N*m 214 kgf*cm 15 ft.*lbf
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INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (for RHD)
1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the engine oil level dipstick guide.
3. Install the engine oil level dipstick guide with the bolt.
  
  10 N*m 102 kgf*cm 7 ft.*lbf
4. Install the engine oil level dipstick.
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INSTALL ENGINE OIL LEVEL DIPSTICK (for RHD)
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INSTALL SKID CONTROL ECU BRACKET (for LHD)

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INSTALL SKID CONTROL ECU BRACKET (for RHD)

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INSTALL AIR CLEANER ASSEMBLY RH
1. Align the air cleaner cases 2 holes to the 2 stud bolts and attach the air cleaner case RH to the boss. Then install the 2 nuts.
  
  5.0 N*m 51 kgf*cm 44 in.*lbf
2. Install the air cleaner filter element to the air cleaner case RH.
3. Install the air cleaner cap RH and secure the 2 clamps.
4. Connect the mass air flow meter connector.
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INSTALL AIR CLEANER ASSEMBLY LH
1. Align the air cleaner cases 2 holes to the 2 stud bolts and attach the air cleaner case LH to the boss. Then install the 2 nuts.
  
  5.0 N*m 51 kgf*cm 44 in.*lbf
2. Install the air cleaner filter element to the air cleaner case LH.
3. Install the air cleaner cap LH and secure the 2 clamps.
4. Connect the mass air flow meter connector.
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INSTALL THROTTLE BODY ASSEMBLY

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INSTALL SERVICE PLUG GRIP

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CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

Note:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see pageClick here).
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INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)
1. Attach the 2 clips to install the deck trim side board LH.
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INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY
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INSTALL ENGINE ROOM SIDE COVER LH
1. Install the engine room side cover LH with the 5 clips.
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INSTALL ENGINE ROOM SIDE COVER RH
1. Install the engine room side cover RH with the 5 clips.

INTAKE MANIFOLD INSTALLATION