INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY


    1. B001YQQE04
      Text in Illustration
      *1 Groove
      *2 Protrusion

      Align the protrusion of a new gasket with the groove of the intake manifold and install the gasket.

    2. Install the throttle body with motor assembly with the 4 bolts.

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

  2. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR

    Click here

  3. INSTALL PURGE VSV


    1. Connect the purge line hose to the intake manifold.

    2. Install the purge VSV to the intake manifold with the bolt.

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

  4. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. Install the vacuum switching valve to the intake manifold with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 2 vacuum hoses to the vacuum switching valve and attach the 3 clamps.

  5. INSTALL STUD BOLT

    Note

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


    1. Using an E5 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

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

  6. INSTALL INTAKE FLANGE


    1. Install the intake flange with the 2 nuts.

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

  7. INSTALL V-BANK COVER PIN


    1. Install the V-bank cover pin to the intake manifold.

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

  8. INSTALL V-BANK COVER BRACKET


    1. Install the V-bank cover bracket with the 2 bolts.

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

  9. INSTALL BRACKET


    1. Install the 2 brackets with the 2 bolts.

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

  10. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. Install the fuel tube to the intake manifold with the bolt.

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

  11. INSTALL INTAKE MANIFOLD


    1. B001WEB

      Place 2 new gaskets on the intake manifold.

    2. Place the intake manifold on the cylinder head.

    3. Install and uniformly tighten the 8 bolts and 2 nuts in several steps.

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

    4. Connect the fuel tube to the No. 2 fuel delivery pipe Click here.

    5. Connect the fuel tube to the fuel delivery pipe Click here.

    6. Attach the 3 wire harness clamps to the 3 wire harness brackets.

    7. Install the bolt.

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

    8. Connect the purge VSV connector.

    9. Connect the purge line hose to the purge VSV.

    10. Connect the vacuum switching valve connector (for ACIS).

    11. Connect the PCV valve hose.

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

    13. Connect the throttle position sensor and throttle control motor connector.

    14. w/o Secondary Air Injection System:


      1. Install the bracket with the 2 bolts.

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

      2. Attach the clamp and connect the manifold absolute pressure sensor connector.

  12. INSTALL AIR TUBE SUB-ASSEMBLY (w/ Secondary Air Injection System)


    1. Install the air tube.

    2. Install the bolt.

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

    3. Install the bracket with the 2 bolts.

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

    4. Attach the clamp and connect the manifold absolute pressure sensor connector.

    5. B001YO6E02
      Text in Illustration
      *1 Projection
      *2 Paint Mark

      Align the paint mark with the projection and connect the No. 2 air injection system hose.

      Tech Tips

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

  13. INSTALL PCV HOSE ASSEMBLY


    1. Install the PCV hose with the bolt.

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

    2. Connect the PCV hose to the PCV pipe of the cylinder head cover LH and RH.

  14. INSTALL EGR VALVE BRACKET


    1. Install the EGR valve bracket with the 3 bolts.

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

    2. Attach the 2 wire harness clamps and PCV hose clamp.

  15. INSTALL NO. 5 WATER BY-PASS PIPE


    1. Install the No. 5 water by-pass pipe with the 2 bolts and connect the 2 water by-pass hoses.

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

  16. ADD ENGINE COOLANT

    Click here

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

    Click here

  18. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  19. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  20. INSTALL AIR CLEANER CAP AND HOSE

    Click here

  21. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  23. INSPECT FOR FUEL LEAK

    Click here

  24. PERFORM INITIALIZATION

    Click here