INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. A01MTUK

      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 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. A01MS8SN02

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

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

    4. Connect the No. 2 water by-pass hose to the intake manifold clamp.

    5. 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 }
    6. A01MRICC01
      *a Groove
      *b Protrusion

      w/o EGR system:


      1. Install a new EGR inlet gasket to the intake manifold.

        Tech Tips

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

      2. Install the EGR hole cover plate to the intake manifold with the 2 nuts.

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

    7. Connect the 7 wire harness clamps to the intake manifold and 2 wire harness clamp brackets.

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

    9. Connect the ventilation hose assembly to the wire harness clamp bracket.

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

    11. Connect the No. 1 fuel pipe clamp to the wire harness clamp bracket.

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

    Click here

  4. CONNECT INLET HEATER WATER HOSE A


    1. A01MTWHC01
      *a View A
      *b Marking
      *c Clip Installation Angle (-15 to 15°)
      *d Upper Side
      *e RH Side

      Connect the inlet heater water hose A to the radiator unit sub-assembly and slide the clip to secure it.

      Note


      • Engage the clip within the area shown in the illustration.

      • Do not apply excessive force to the inlet heater water hose A.

  5. INSTALL OUTLET HEATER WATER HOSE A


    1. A01MU1SC01
      *a View A
      *b View B
      *c Marking
      *d Clip Installation Angle (30 to 60°)
      *e Clip Installation Position
      *f Upper Side
      *g RH Side
      *h Front Side

      Install the outlet heater water hose A to the radiator unit sub-assembly and No. 2 water by-pass pipe and slide the 2 clips to secure it.

      Note


      • Engage the clip within the area shown in the illustration.

      • Do not apply excessive force to the outlet heater water hose A.

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

  6. INSTALL PURGE VALVE (PURGE VSV)

    Click here

  7. INSTALL VACUUM SENSOR ASSEMBLY

    Click here

  8. INSTALL INJECTOR DRIVER

    Click here

  9. CONNECT INVERTER RESERVE TANK ASSEMBLY


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

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

  10. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  11. INSTALL INLET NO. 1 AIR CLEANER

    Click here

  12. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here