INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. Using an E6 "TORX" socket wrench, install the 4 stud bolts to the intake manifold.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  2. INSTALL EGR HOLE COVER PLATE (w/o EGR System)


    1. A000R16E02
      Text in Illustration
      *a Groove
      *b Protrusion

      Install a new EGR inlet gasket and EGR hole cover plate to the intake manifold with the 2 nuts.

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

      Note

      Align the protrusion of the EGR inlet gasket with the groove of the intake manifold.

  3. INSTALL INTAKE MANIFOLD


    1. Install a new gasket to the intake manifold.

    2. Temporarily install the intake manifold and intake manifold stay with the 7 bolts.

      Tech Tips

      If an intake manifold stay is deformed or damaged, replace it.

    3. A000S8JE02

      Tighten the 7 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    4. Install the 2 wire harness clamp brackets to the intake manifold with the 3 bolts.

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

    5. Attach the clamp to connect the No. 2 water by-pass hose to the intake manifold.

    6. Attach the 7 wire harness clamps to connect the wire harness to the 2 wire harness clamp brackets and intake manifold.

    7. Attach the clamp to connect the ventilation hose to the wire harness clamp bracket.

    8. Connect the ventilation hose to the intake manifold, and slide the clip to secure the hose.

    9. Connect the No. 2 fuel vapor feed hose to the intake manifold.

    10. Attach the clamp to connect the fuel tube to the wire harness clamp bracket.

  4. INSTALL NO. 2 EGR PIPE (w/ EGR System)

    Click here

  5. INSTALL OUTLET HEATER WATER HOSE A


    1. Install the water hose set to the outlet heater water hose A.

    2. B002BASE04
      Text in Illustration
      *a Paint Mark
      *b Protrusion
      *c Upper Side of Vehicle
      *d Front Side of Vehicle

      Install the outlet heater water hose A to the No. 2 water by-pass pipe, and slide the hose clamp to secure the hose.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

    3. Connect the outlet heater water hose A to the heater unit, and slide the hose clamp to secure the hose.

  6. CONNECT INLET HEATER WATER HOSE A

    Click here

  7. INSTALL PURGE VSV

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  8. INSTALL VACUUM SENSOR ASSEMBLY

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  9. CONNECT INVERTER RESERVE TANK ASSEMBLY (for RHD)


    1. Install the inverter reserve tank assembly to the No. 1 inverter reserve tank bracket with the 2 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  10. INSTALL INJECTOR DRIVER

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  11. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  12. INSTALL NO. 1 AIR CLEANER INLET

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  13. INSTALL COOL AIR INTAKE DUCT SEAL

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  14. INSTALL ENGINE ROOM SIDE COVER

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