INTAKE MANIFOLD INSTALLATION


  1. INSTALL INTAKE MANIFOLD


    1. Install the vacuum hose clamp with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    2. Install the union to check valve hose, No. 2 ventilation hose and No. 1 throttle body hose.

    3. Install the No. 1 intake manifold insulator.

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

    5. Set the intake manifold.

    6. Connect the engine wire.


      1. A01CF25

        Connect the engine wire harness with the 2 bolts.

      2. A01CATI

        Connect the connector and wire harness clamp.

      3. A01CBF3

        Install the earth bolt.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      4. Connect the 4 connectors.

      5. A01CD02

        Connect the 4 connectors.

      6. A01CD1G

        Install the earth bolt.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      7. Connect the connector and 3 wire harness clamps.

      8. A01CAQ1

        Connect the earth connector and wire harness clamp.

      9. A01CGIS

        Connect the terminal B with the nut and install the terminal cap.

        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      10. Connect the 2 connectors and 2 wire harness clamps.

      11. A01CBKV

        Connect the compressor connector and clamp.

    7. Using an E7 "TORX" wrench, install the 2 stud bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    8. Install the intake manifold with the 5 bolts and 2 nuts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    9. Connect the union to check valve hose to the hose clamp.

    10. Connect the oxygen sensor connector and clamp.

  2. CONNECT UNION TO CHECK VALVE HOSE


    1. Connect the union to check valve hose.

  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01CE68

      Install 4 new insulators into the cylinder head.

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

    3. A01CCM5E08
      Text in Illustration
      *1 O-ring
      *2 Fuel Injector
      *3 Insulator
      *4 Fuel Delivery Pipe

      Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 2 bolts.

      Note

      Be careful not to drop the fuel injectors when installing the fuel delivery pipe.

    4. Check that the fuel injector rotates smoothly.

      If the fuel injector does not rotate smoothly, replace the O-ring.

    5. A01CDXZ

      Tighten the 2 bolts to the specified torque.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    6. A01CGBI

      Connect the 4 fuel injector connectors.

    7. Connect the oil control valve connector.

    8. Install the 2 wire harness clamps.

  4. INSTALL NO. 2 VENTILATION HOSE


    1. A01CF7HE03

      Connect the ventilation hose to the ventilation valve.

      Note

      Make sure that the paint mark and hose clamp are positioned as shown in the illustration after connecting the hose.

  5. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01CCPB

      Install the fuel tube to the fuel hose clamp.

    2. A01CGER

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

      Note


      • Check that there is no damage or foreign matter on the fuel pipe connectors.

      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

    3. Close the No. 1 fuel pipe clamp.

      Tech Tips

      The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected.

  6. INSTALL THROTTLE BODY


    1. Install the throttle body Click here.

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  8. INSPECT FOR FUEL LEAK


    1. Check fuel pump operation.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the engine switch on (IG) and turn the intelligent tester 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 inlet tube from the fuel line. Check that sounds of fuel flowing in 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 is no fuel leakage after performing maintenance anywhere on the fuel system. If there is a fuel leak, repair or replace parts if necessary.

    3. Turn the engine switch off.

    4. Disconnect the intelligent tester from the DLC3.