INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL INTAKE MANIFOLD


    1. B003X7N

      Install 2 new No. 1 intake manifold to head gaskets to each cylinder head sub-assembly as shown in the illustration.

      Note


      • Align the port holes of the No. 1 intake manifold to head gaskets and cylinder head sub-assembly.

      • Make sure that the No. 1 intake manifold to head gaskets are installed in the correct direction.

    2. Temporarily install the intake manifold to the cylinder head sub-assembly with the 4 bolts and 4 nuts.

    3. Uniformly tighten the 4 bolts and 4 nuts.

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

  2. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

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  3. CONNECT WIRE HARNESS

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  4. INSTALL NO. 1 FUEL TUBE SUB-ASSEMBLY

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  5. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  6. INSTALL NO. 2 FUEL TUBE SUB-ASSEMBLY

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  7. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    Do not apply oil to the bolts listed below.

    Oil Application Prohibited Bolt
    Bolt for Intake Air Surge Tank Assembly and Intake Manifold

    1. for LHD:


      1. Install the No. 1 hose to hose tube to the intake air surge tank assembly with the 2 bolts.

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

    2. Install a new air surge tank to intake manifold gasket to the intake air surge tank assembly.

    3. Set the intake air surge tank assembly on the intake manifold.

    4. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

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

    5. Install and uniformly tighten the 5 bolts and 2 nuts.

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

    6. Connect the No. 2 surge tank stay to the intake air surge tank assembly with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    7. B003X9BC01
      *1 Torque Wrench Fulcrum Length

      Using SST, connect the No. 2 water by-pass pipe to the intake air surge tank assembly with the bolt.

      SST
      09290-41010
      Torque:
      Specified tightening torque
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using SST (fulcrum length of 69 mm (2.72 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        14.7 N*m (150 kgf*cm, 11 ft.*lbf)

    8. Engage the clamp to connect the No. 2 fuel tube sub-assembly.

    9. Connect the 6 wire harness clamps to the intake air surge tank assembly.

    10. for RHD:


      1. Connect the wire harness clamp bracket with the bolt.

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

    11. Engage the 2 clamps to connect the No. 2 water by-pass hose to the intake air surge tank assembly.

    12. Connect the ventilation hose assembly to the intake air surge tank assembly and slide the clip to secure it.

    13. Connect the purge valve (purge VSV) to the intake air surge tank assembly with the bolt.

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

    14. Connect the No. 1 fuel vapor feed hose to the intake air surge tank assembly.

    15. Connect the purge valve (purge VSV) connector.

  8. CONNECT VACUUM HOSE ASSEMBLY (for LHD)


    1. Connect the union to check valve hose to the vacuum pump assembly and slide the clip to secure it.

    2. Connect the vacuum hose assembly to the No. 1 hose to hose tube and slide the clip to secure it.

  9. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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  10. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  12. INSPECT FOR FUEL LEAK

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