INTAKE MANIFOLD INSTALLATION


  1. INSTALL INTAKE MANIFOLD


    1. Install the wire harness clamp bracket to the intake manifold with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01G73TE03
      Text in Illustration
      *a Black

      Connect the 2 vacuum hoses and check that the No. 1 check valve is installed as shown in the illustration.

    3. Check the tumble control valves (w/ TCV).

      Note

      The tumble control valves may be damaged if they are not closed before installing the intake manifold.

      Tech Tips

      Connect the battery to the terminals of the intake air control valve actuator to operate the motor and close the tumble control valves Click here.

    4. Install a new intake manifold gasket to the intake manifold.

    5. A01G8IHE01

      Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration (w/ TCV).

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    6. A01G81VE01

      Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration (w/o TCV).

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    7. A01G4V9E01

      Connect the intake air control valve actuator connector and 2 wire harness clamps (w/ TCV).

    8. Connect the 2 wire harness clamps (w/o TCV).

    9. Install the wire harness clamp with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Text in Illustration
      *A w/ TCV
      *B w/o TCV
    10. A01G4TD

      Install the wire harness clamp bracket to the intake manifold with the bolt.

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

    11. Connect the 3 wire harness clamps and connector.

    12. Connect the fuel vapor feed hose to the intake manifold.

    13. Install the 2 wire harness clamp brackets to the intake manifold with the 2 bolts.

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

  2. INSTALL FUEL DELIVERY PIPE


    1. A01G6THE01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *a Fuel Delivery Pipe Side
      *b Cylinder Head Side

      Install 4 new injector vibration insulators to the cylinder head.

    2. Install the 2 fuel delivery spacers onto the cylinder head.

      Tech Tips

      Install the fuel delivery spacer so that the longer protrusion is on the cylinder head side.

    3. Install the fuel delivery pipe with the 4 fuel injector assemblies and install the 2 bolts.

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

      Note


      • Do not drop the fuel injector assemblies when installing the fuel delivery pipe.

      • Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe.

  3. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01G50PE02
      Text in Illustration
      *1 Fuel Pipe
      *2 Fuel Tube Connector
      *3 Nylon Tube
      *4 O-ring
      *5 Retainer

      Push the fuel tube connector to the fuel pipe until the fuel tube connector makes a "click" sound.

      Note


      • Before connecting the fuel tube connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe.

      • After connecting the fuel tube connector and fuel pipe, check that they are securely connected by trying to pull them apart.

    2. A01G562

      Install the No. 1 fuel pipe clamp.

    3. Connect the fuel tube sub-assembly to the fuel hose clamp.

  4. CONNECT UNION TO VACUUM TUBE HOSE


    1. Connect the union to vacuum tube hose to the intake manifold.

  5. CONNECT NO. 2 VENTILATION HOSE


    1. Connect the No. 2 ventilation hose to the intake manifold.

  6. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. Install the vacuum switching valve assembly to the intake manifold with the bolt.

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

    2. Connect the 2 vacuum hoses and connector.

    3. Connect the union to vacuum tube hose and wire harness clamp.

  7. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  8. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. Install the front outer cowl top panel sub-assembly with the 10 bolts.

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

    2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

    3. A01G885E01

      Connect the connector to install the wire harness to the front outer cowl top panel sub-assembly.

    4. Engage the 2 clamps (B).

    5. w/ Wiper Deicer System:

      Engage the clamp (A).

  9. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  10. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Click here

  11. INSPECT FOR FUEL LEAK


    1. Check fuel pump operation.


      1. Connect the GTS to the DLC3.

      2. Turn the engine switch on (IG) and turn the GTS on.

        Note

        Do not start the engine.

      3. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.

      4. Check for pressure in the fuel tube sub-assembly from the fuel pipe. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.

    2. Inspect for fuel leaks.


      1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

    3. Turn the engine switch off.

    4. Disconnect the GTS from the DLC3.