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INTAKE MANIFOLD INSTALLATION

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PROCEDURE


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    INSTALL INTAKE AIR SURGE TANK ASSEMBLY


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

    2. Temporarily install the intake air surge tank assembly to the cylinder block sub-assembly with the 8 bolts and 2 nuts.

    3. B00670WN01

      Tighten the 8 bolts and 2 nuts in the order shown in the illustration.

      21 N*m 214 kgf*cm 15 ft.*lbf

    4. Connect the wire harness bracket to the intake air surge tank assembly with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
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    CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. Connect the No. 1 fuel pipe sub-assembly to the intake air surge tank assembly with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
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    INSTALL NO. 2 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. Install the No. 2 V-bank cover bracket sub-assembly to the intake air surge tank assembly with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
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    INSTALL V-BANK COVER BRACKET SUB-ASSEMBLY


    1. Install the V-bank cover bracket sub-assembly to the intake air surge tank assembly with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
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    INSTALL FUEL TUBE SUB-ASSEMBLY

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    INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

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    INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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    INSTALL NO. 1 DELIVERY PIPE SPACER

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    INSTALL INJECTOR VIBRATION INSULATOR

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    INSTALL FUEL INJECTOR ASSEMBLY

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    INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the water by-pass pipe sub-assembly to the intake air surge tank assembly with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
    2. B006539C01
      *1 Heater Water Inlet Hose
      *2 Heater Water Outlet Hose
      *3 No. 3 Water By-pass Hose
      *4 Water By-pass Hose
      *5 No. 5 Water By-pass Hose

      Connect the heater water inlet hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    3. Connect the heater water outlet hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    4. Connect the No. 5 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    5. Connect the water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    6. Connect the No. 3 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    7. Install the 2 water hose sets to the heater water inlet hose and heater water outlet hose.

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    INSTALL INJECTOR DRIVER BRACKET


    1. Install the 2 injector driver brackets to the intake air surge tank assembly with the 4 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
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    CONNECT VENTILATION HOSE


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

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    INSTALL FUEL VAPOR FEED HOSE


    1. Install the fuel vapor feed hose to the intake air surge tank assembly and slide the clip to secure it.

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    CONNECT VACUUM HOSE SUB-ASSEMBLY


    1. Connect the vacuum hose sub-assembly to the intake air surge tank assembly.

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    CONNECT NO. 5 ENGINE WIRE


    1. Engage the 4 clamps and connect the No. 5 engine wire to the intake air surge tank assembly.

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    ENGAGE ENGINE WIRE


    1. Engage the wire harness to the engine room ECU box.

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    2. Connect the engine wire harness connector.

    3. Engage the claw and connect the engine wire harness.

    4. B0066CIC02
      B0067U9 Bolt
      B00679M Connector

      Connect the 7 connectors.

    5. Engage the 7 clamps.

    6. Install the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
    7. B006600C01
      *a Bolt (A)
      *b Bolt (B)
      B0067U9 Bolt
      B00679M Connector

      Connect the 4 connectors.

    8. Engage the 2 clamps.

    9. Install the bolt (A) and (B).

      Bolt (A)
      10 N*m 102 kgf*cm 7 ft.*lbf
      Bolt (B)
      12 N*m 122 kgf*cm 9 ft.*lbf

    10. for LHD without differential pressure sensor:


      1. B0065XEC01
        B0067U9 Bolt B00679M Nut
        B00683Y Connector B0067MG Fuel Tube Sub-assembly

        Engage the fuel tube sub-assembly to the engine wire.

      2. Connect the 12 connectors.

      3. Engage the 4 clamps.

      4. Install the 2 bolts and 4 nuts.

        10 N*m 102 kgf*cm 7 ft.*lbf

    11. for LHD with differential pressure sensor:


      1. B0065GAC01
        B0067U9 Bolt B00679M Nut
        B00683Y Connector B0067MG Fuel Tube Sub-assembly

        Engage the fuel tube sub-assembly to the engine wire.

      2. Connect the 14 connectors.

      3. Engage the 4 clamps.

      4. Install the 2 bolts and 4 nuts.

        10 N*m 102 kgf*cm 7 ft.*lbf

    12. for RHD without differential pressure sensor:


      1. B0065ROC01
        B0067U9 Bolt B00679M Nut
        B00683Y Connector B0067MG Fuel Tube Sub-assembly

        Engage the fuel tube sub-assembly to the engine wire.

      2. Connect the 12 connectors.

      3. Engage the 5 clamps.

      4. Install the 2 bolts and 4 nuts.

        10 N*m 102 kgf*cm 7 ft.*lbf

    13. for RHD with differential pressure sensor:


      1. B0067WSC01
        B0067U9 Bolt B00679M Nut
        B00683Y Connector B0067MG Fuel Tube Sub-assembly

        Engage the fuel tube sub-assembly to the engine wire.

      2. Connect the 14 connectors.

      3. Engage the 5 clamps.

      4. Install the 2 bolts and 4 nuts.

        10 N*m 102 kgf*cm 7 ft.*lbf
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    INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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    INSTALL ENGINE ROOM ECU COVER

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    CONNECT UNION TO CHECK VALVE HOSE


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

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    INSTALL INJECTOR DRIVER

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    INSTALL FRONT SUSPENSION UPPER BRACE BRACKET


    1. Install the front suspension upper brace bracket to the vehicle body with the 2 nuts.

      29 N*m 296 kgf*cm 21 ft.*lbf

    2. for LHD:


      1. Connect the union to check valve hose to the front suspension upper brace bracket.

    3. for RHD:


      1. Connect the No. 2 engine wire to the front suspension upper brace bracket.

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    INSTALL FRONT SUSPENSION UPPER TO COWL BRACE RH

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    INSTALL FRONT SUSPENSION UPPER TO COWL BRACE LH

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    INSTALL PURGE VALVE (PURGE VSV)

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    INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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    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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    INSPECT FOR FUEL LEAK

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