INTAKE MANIFOLD INSTALLATION

PROCEDURE

1. INSTALL INTAKE FLANGE (w/o EGR System)

   
   

   1. Install a new gasket to the intake manifold.

   2. Install the intake flange with the 3 bolts.

      Torque:

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

   3. Install the engine cover joint to the intake flange.

      Torque:

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

2. INSTALL INTAKE MANIFOLD

   
   
   1. 

      *a	Top
      *b	Rear

      Connect the purge line hose to the intake manifold, and slide the clamp to secure the hose.

      Tech Tips

      Make sure the hose clamp is oriented as shown in the illustration.

   2. Install the vacuum hose to the intake manifold.

   3. Install the wiring harness clamp bracket with the bolt.

      Torque:

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

   4. Install a new No. 1 intake manifold to head gasket to the intake manifold.

   5. Install the intake manifold to the vehicle.

3. INSTALL FUEL DELIVERY PIPE

   Click here

4. CONNECT FUEL TUBE SUB-ASSEMBLY

   Click here

5. CONNECT NO. 1 EGR PIPE (w/ EGR System)

   
   

   1. Install a new gasket to the No. 1 EGR pipe.

      Note

      Make sure the claws of the gasket face the No. 1 EGR pipe.

   2. Temporarily install the No. 1 EGR pipe with the 3 bolts and nut.

   3. Tighten the 3 bolts and nut to connect the No. 1 EGR pipe.

      Torque:

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

6. CONNECT INTAKE MANIFOLD

   
   

   1. Temporarily install the intake manifold with the 6 bolts.

   2. 

      Tighten the 6 bolts in the order shown in the illustration.

      Torque:

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

   3. Connect the No. 2 PCV hose to the intake manifold, and slide the clamp to secure the hose.

7. CONNECT ENGINE WIRE

   
   

   1. Attach the 6 clamps and connect the engine wire.

   2. Connect the heated oxygen sensor connector.

8. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR

   Click here

9. INSTALL EGR VALVE ASSEMBLY (w/ EGR System)

   Click here

10. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

11. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

12. INSTALL OUTER COWL TOP PANEL (for LHD)

    
    

    1. w/o Performance Rod:

       
       

       1. Install the outer cowl top panel with the 13 bolts and 2 nuts.

          Torque:

          for bolt

          5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

          for nut

          20 N*m  { 204 kgf*cm, 15 ft.*lbf }

       2. Attach the 4 clamps and connect the wire harness.

       3. Connect the connector.

          

          	Connector		Bolt
          	Nut	-	-

    2. w/ Performance Rod:

       
       

       1. Install the outer cowl top panel with the 13 bolts.

          Torque:

          5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

       2. Attach the 4 clamps and connect the wire harness.

       3. Connect the connector.

13. INSTALL OUTER COWL TOP PANEL (for RHD)

    
    

    1. w/o Performance Rod:

       
       

       1. Install the outer cowl top panel with the 13 bolts and 2 nuts.

          Torque:

          for bolt

          5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

          for nut

          20 N*m  { 204 kgf*cm, 15 ft.*lbf }

       2. Attach the 4 clamps and connect the wire harness.

       3. Connect the connector.

          

          	Connector		Bolt
          	Nut	-	-

    2. w/ Performance Rod:

       
       

       1. Install the outer cowl top panel with the 13 bolts.

          Torque:

          5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

       2. Attach the 4 clamps and connect the wire harness.

       3. Connect the connector.

14. INSTALL SUSPENSION TOWER DAMPER (w/ Performance Rod)

    
    

    1. Install the suspension tower damper with the 2 nuts.

       Torque:

       20 N*m  { 204 kgf*cm, 15 ft.*lbf }

15. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

16. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

17. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

    Click here

18. INSTALL DECK FLOOR BOX LH (w/ Spare Tire)

    Click here

19. INSTALL REAR DECK FLOOR BOX (w/ Spare Tire)

    Click here

20. INSTALL NO. 3 DECK BOARD SUB-ASSEMBLY

    Click here

21. ADD ENGINE COOLANT

    Click here

22. INSPECT FOR COOLANT LEAK

    Click here

23. INSPECT FOR FUEL LEAK

    Click here