INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. B00779I

      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 No. 1 intake manifold to head gasket to each cylinder head sub-assembly.

      Note


      • Align the port holes of the No. 1 intake manifold to head gaskets with those of the cylinder head sub-assembly.

      • Make sure that the 2 No. 1 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 4 bolts and 4 nuts.

    3. B0073TAC02
      B0073AQ Bolt
      B0077IM Nut
      B0077LI Front

      Tighten the 4 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 ENGINE WIRE

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  5. CONNECT FUEL TUBE SUB-ASSEMBLY

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  6. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    Do not apply oil to the following bolts and nuts:

    Oil Application Prohibited Bolt and Nut
    Bolt and Nut for Intake Air Surge Tank Assembly and Intake Manifold
    Bolt for No. 2 Surge Tank Stay and Intake Air Surge Tank Assembly

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

    2. Install a new air surge tank to intake manifold gasket to the intake air surge tank assembly.

    3. Temporarily install the intake air surge tank assembly to the intake manifold with the 6 bolts and 2 nuts.

    4. B0073QXC02
      B0073AQ Bolt
      B0077IM Nut

      Using a 5 mm hexagon socket wrench, tighten the 6 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. Connect the No. 2 surge tank stay to the intake air surge tank assembly with the bolt.

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

    7. Connect the No. 3 water by-pass pipe to the intake air surge tank assembly with the bolt.

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

    8. for RHD:


      1. Engage the wire harness clamp to the intake air surge tank assembly.

    9. Engage the 4 wire harness clamps to the intake air surge tank assembly.

    10. Connect the No. 2 water by-pass hose to the intake air surge tank assembly clamp.

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

    12. Connect the ventilation hose assembly to the PCV valve (ventilation valve sub-assembly) and slide the clip to secure it.

    13. Install the purge valve (purge VSV) to the intake air surge tank assembly with the bolt.

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

    14. Connect the No. 1 fuel vapor feed hose to the purge valve (purge VSV).

    15. Connect the purge valve (purge VSV) connector.

  7. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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  8. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  10. INSPECT FOR FUEL LEAK

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