INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. 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.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  2. 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.

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

      Tech Tips

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

  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    Click here

  4. 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.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Text in Illustration
      B001XPG Bolt
      B001WGT Nut

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

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

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

      Torque:
      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.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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

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

    8. for Manual Transmission:

      Connect the clutch flexible hose bracket with the nut.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    9. B001XEPE02
      Text in Illustration
      *a Front
      *b RH

      Connect the No. 1 PCV hose.

      Tech Tips

      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.

  5. INSTALL AIR TUBE (w/ Secondary Air Injection System)


    1. B001WMME02
      Text in Illustration
      *1 Paint Mark
      *a Top
      *b RH Side

      for Bank 1 Side:

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

      Tech Tips

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

    2. B001XYTE02
      Text in Illustration
      *1 Paint Mark
      *a Top
      *b LH Side

      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.

      Tech Tips

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

    3. Install the 3 bolts.

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

    4. Connect the No. 3 air hose.

  6. INSTALL NO. 1 AIR CLEANER HOSE


    1. B001Y7ZE02
      Text in Illustration
      *a Protrusion
      *b Groove
      *c Top
      *d Front

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

      Torque:
      2.5 N*m  { 25 kgf*cm, 22 in.*lbf }

    2. Install the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

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

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  8. ADD ENGINE COOLANT

    Click here

  9. INSPECT FOR COOLANT LEAK

    Click here

  10. INSPECT FOR FUEL LEAK

    Click here

  11. INSTALL V-BANK COVER


    1. B001XVZE02
      Text in Illustration
      *1 Pin
      *2 Hook

      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.

  12. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  13. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  14. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here