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INTAKE MANIFOLD INSTALLATION

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PROCEDURE


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    INSTALL STUD BOLT

    Note:

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


    1. Using the E8 "TORX" socket wrench, install the 2 stud bolts.

      8.0 N*m 82 kgf*cm 71 in.*lbf
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    INSTALL INTAKE MANIFOLD


    1. B001YRB

      Set a new gasket on each cylinder head.

      Note:

      • Align the port holes of the gasket and cylinder head.

      • Be careful of the installation direction.

    2. Set the intake manifold on the cylinder heads.

    3. Install and uniformly tighten the 6 bolts and 4 nuts in several passes.

      21 N*m 214 kgf*cm 15 ft.*lbf
      Tip:

      Tighten the inner installation bolts of the intake manifold before tightening the outer bolts.

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    INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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    INSTALL INTAKE AIR SURGE TANK


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

    2. B001WAQE02

      Install the intake air surge tank with the 4 bolts and 2 nuts in the order shown in the illustration.

      28 N*m 286 kgf*cm 21 ft.*lbf
      Table 1. Text in Illustration
      B001XPG Bolt
      B001WGT Nut

    3. Install the throttle body bracket with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    4. Install the No. 1 surge tank stay with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    5. Attach the wire harness clamp.

    6. Install the bracket with the bolt and attach the 2 wire harness clamps.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    7. Install the No. 2 surge tank stay with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    8. for Manual Transmission:

      Connect the clutch flexible hose bracket with the nut.

      20 N*m 204 kgf*cm 15 ft.*lbf
    9. B001XEPE02

      Connect the No. 1 PCV hose.

      Table 2. Text in Illustration
      *a Front
      *b RH
      Tip:

      Connect the No. 1 PCV hose so that the direction of the hose clamp is as indicated in the illustration.

    10. Connect the No. 1 vacuum switching valve connector.

    11. Connect the purge line hose.

    12. Connect the throttle body connector.

    13. Connect the No. 4 water by-pass hose.

    14. Connect the No. 5 water by-pass hose.

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    INSTALL AIR TUBE (w/ Secondary Air Injection System)


    1. B001WMME02

      for Bank 1 Side:

      Align the paint mark with the projection and connect the air tube assembly to the emission control valve set.

      Table 3. Text in Illustration
      *1 Paint Mark
      *a Top
      *b RH Side
      Tip:

      Make sure the direction of the hose clamp is as shown in the illustration.

    2. B001XYTE02

      for Bank 2 Side:

      Align the paint mark with the projection and connect the air tube assembly to the No. 2 emission control valve set.

      Table 4. Text in Illustration
      *1 Paint Mark
      *a Top
      *b LH Side
      Tip:

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Install the 3 bolts.

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

    4. Connect the No. 3 air hose.

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    INSTALL NO. 1 AIR CLEANER HOSE


    1. B001Y7ZE02

      Install the No. 1 air cleaner hose with the 2 hose clamps.

      2.5 N*m 25 kgf*cm 22 in.*lbf
      Table 5. Text in Illustration
      *a Protrusion
      *b Groove
      *c Top
      *d Front

    2. Install the bolt.

      5.0 N*m 51 kgf*cm 44 in.*lbf

    3. Connect the vacuum hose and No. 2 PCV hose.

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    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

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    ADD ENGINE COOLANT

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    INSPECT FOR COOLANT LEAK

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    INSPECT FOR FUEL LEAK

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    INSTALL V-BANK COVER


    1. B001XVZE02

      Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.

      Table 6. Text in Illustration
      *1 Pin
      *2 Hook
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    INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

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    INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

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    INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

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