INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. A002C52

      Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

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

  2. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET


    1. Install 2 new No. 1 intake manifold to head gaskets to each cylinder head sub-assembly.

      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.

  3. INSTALL INTAKE MANIFOLD


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

    2. A00291OC02
      B003ZIE Bolt
      B003Z8F Nut

      Tighten the 4 bolts and 4 nuts in the order shown in the illustration.

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

  4. INSTALL INJECTOR VIBRATION INSULATOR

    Click here

  5. INSTALL NO. 1 DELIVERY PIPE SPACER

    Click here

  6. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

    Click here

  7. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  8. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A0028D8

      Install the No. 2 engine mounting stay RH to the intake manifold and engine mounting insulator sub-assembly RH with the bolt.

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

    2. Install the wire harness clamp bracket to the No. 2 engine mounting stay RH with the bolt.

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

    3. Engage the wire harness clamp to the wire harness clamp bracket.

    4. A0028CDC01
      B003ZIE Bolt
      B003Z8F Nut

      Install the No. 2 engine mounting stay RH to the engine moving control rod with the bolt and 2 nuts.

      Torque:
      Bolt:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Nut:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  9. INSTALL NO. 1 V-BANK COVER BRACKET

    Tech Tips

    Perform this procedure only when replacement of the No. 1 V-bank cover bracket is necessary.


    1. Install the 2 No. 1 V-bank cover brackets to the intake air surge tank assembly.

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

  10. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET


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

  11. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    Do not apply oil to the bolts and nuts as listed below:

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

    1. Temporarily install the intake air surge tank assembly to the intake manifold with the 5 bolts and 2 nuts.

    2. Temporarily install the No. 2 surge tank stay to the intake air surge tank assembly and camshaft housing RH with the 2 bolts.

    3. A002AX8C02
      B003ZIE Bolt
      B003Z8F Nut

      Tighten the 5 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A0028A4N01

      Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    5. A002BLXC01
      *1 Vacuum Hose Sub-assembly
      *2 No. 2 Air Tube

      Engage the clamp to connect the No. 2 air tube to the intake air surge tank assembly.

    6. Engage the 2 clamps to connect the vacuum hose sub-assembly to the intake air surge tank assembly.

    7. A00296J

      Engage the 2 clamps to connect the vacuum hose sub-assembly to the intake air surge tank assembly.

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

  12. CONNECT PURGE VALVE (PURGE VSV)


    1. 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 }

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

  13. CONNECT VENTILATION HOSE


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

  14. INSTALL RESERVOIR BRACKET (for RHD)

    Click here

  15. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for RHD)

    Click here

  16. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  17. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  18. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  21. INSPECT FOR FUEL LEAK

    Click here

  22. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here