INTAKE MANIFOLD INSTALLATION

  1. INSTALL INTAKE MANIFOLD

    1. Install the wire harness clamp bracket with the bolt.

      A011UPG
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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

      A011UV4E03
      Text in Illustration
      *a Black

    3. Check the tumble control valves.

      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 actuator to operate the motor and close the valves Click here.

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

    5. Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration.

      A011T1NE01
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    6. Connect the intake air control actuator connector and 2 wire harness clamps.

      A011SEI

    7. Install the wire harness clamp with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    8. Install the wire harness clamp bracket with the bolt.

      A011V5I
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    9. Connect the 3 wire harness clamps and connector.

    10. Connect the fuel vapor feed hose.

    11. Install the 2 wire harness clamp brackets with the 2 bolts.

      A011RLU
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    1. Install 4 new injector vibration insulators to the cylinder head.

      A011TK9E01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *a Fuel Delivery Pipe Side
      *b Cylinder Head Side

    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 sub-assembly 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 injectors when installing the fuel delivery pipe sub-assembly.

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

  3. CONNECT FUEL TUBE SUB-ASSEMBLY

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

      A011TIPE02
      Text in Illustration
      *1 Fuel Pipe
      *2 Fuel Tube Connector
      *3 Nylon Tube
      *4 O-ring
      *5 Retainer

      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. Install the No. 1 fuel pipe clamp.

      A011RQA

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

  4. CONNECT UNION TO CONNECTOR TUBE HOSE

    1. Connect the union to connector 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 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 connector 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.

  9. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  11. INSPECT FOR FUEL LEAK

    1. Check fuel pump operation.

      1. Connect the Techstream to the DLC3.

      2. Turn the ignition switch to ON and turn the Techstream on.

        Note

        Do not start the engine.

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

      4. Check for pressure in the fuel inlet tube from the fuel line. 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 ignition switch off.

    4. Disconnect the Techstream from the DLC3.