INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. Using an E6 "TORX" socket wrench, install the 2 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 intake manifold to head gasket to each cylinder head sub-assembly.

      Note


      • Align the port holes of the intake manifold to head gaskets and cylinder head sub-assembly.

      • Make sure that the 2 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 6 bolts and 4 nuts.

    3. B006RAJC01
      B006QOD Bolt
      B006LKF Nut

      Tighten the 6 bolts and 4 nuts in the order shown in the illustration.

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

  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  4. CONNECT FUEL TUBE SUB-ASSEMBLY

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  5. 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
    Bolt for No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    Bolt for Throttle Body Bracket and Intake Air Surge Tank Assembly

    1. Install the plug to the intake air surge tank assembly and slide the clip to secure it.

      Tech Tips

      Perform this procedure only when replacement of the plug is necessary.

    2. Install 3 new intake air surge tank gaskets to the intake manifold.

    3. Temporarily install the intake air surge tank assembly to the intake manifold with the 4 bolts and 2 nuts.

    4. B006P87C02
      B006QOD Bolt
      B006LKF Nut

      Using a 5 mm hexagon socket wrench, tighten the 4 bolts in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

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

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    6. Temporarily install the No. 1 surge tank stay to the intake air surge tank assembly and cylinder head cover sub-assembly with the 2 bolts.

    7. B006NJ5N01

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

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

    8. Temporarily install the throttle body bracket to the intake air surge tank assembly with the 2 bolts.

    9. B006KHQN01

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

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

    10. Connect the intake air control valve (for ACIS) connector.

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

    12. Connect the fuel vapor feed hose to the intake air surge tank assembly.

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

  6. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. Install the No. 2 engine mounting stay RH to the intake manifold with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. B006LF6

      Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

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

  7. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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

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  9. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  10. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  11. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for LHD)

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

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  13. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

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  14. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

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

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  16. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for LHD)

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  17. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for RHD)

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  18. INSPECT WASHER NOZZLE

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  19. 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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  20. INSPECT FOR FUEL LEAK

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