INTAKE MANIFOLD INSTALLATION


  1. INSTALL INTAKE MANIFOLD


    1. A01NE8S

      Set 2 new intake manifold gaskets on each cylinder head.

      Note


      • Align the port holes of the gaskets and cylinder head.

      • Make sure that the gaskets are installed in the correct direction.

    2. A01NE99

      Set the intake manifold on the cylinder head.

    3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.

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

  2. INSTALL FUEL INJECTOR ASSEMBLY


    1. A01NHAPE03
      Text in Illustration
      *1 New O-ring

      Apply a light coat of spindle oil or gasoline to new O-rings, and install them to each injector.

    2. A01NFRZE01

      Apply a light coat of spindle oil or gasoline where the fuel delivery pipe contacts each O-ring.

    3. Push and twist each fuel injector to install them into the fuel delivery pipe.

    4. Position each fuel injector connector outward.

      Note


      • Be careful not to twist the O-rings.

      • After installing a fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.

    5. A01NE85E01

      Install 6 new injector vibration insulators to the intake manifold.

    6. Place the fuel delivery pipe with the 6 fuel injectors in position on the intake manifold.

      Note

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

    7. A01NGMV

      Temporarily install the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

      Note

      After installing the fuel injectors, check that they turn smoothly. If not, reinstall the injectors with new O-rings.

    8. A01NFMA

      Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    9. A01NGCM

      Connect the 6 fuel injector connectors.

  3. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01NFNFE06
      Text in Illustration
      *1 No. 2 Fuel Pipe Clamp
      *2 Retainer
      *3 Fuel Tube Connector
      *4 O-ring
      *5 Pipe

      Push in the tube connector onto the pipe until the tube connector makes a "click" sound.

      Note


      • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.

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

    2. Install the No. 2 fuel pipe clamp.

  4. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A01NFDW

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

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

  5. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A01NGMS

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

      Torque:
      Bolt
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Nut
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  6. INSTALL EGR DELIVERY CHAMBER


    1. A01NGB1

      Set a new No. 2 intake manifold gasket.

    2. A01NHNVE01
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

      Install the EGR delivery chamber.

    3. A01NCSW

      Connect the 2 water hoses and connector (w/ EGR System).

  7. INSTALL NO. 2 EGR PIPE (w/ EGR System)


    1. A01NG7P

      Install 2 new gaskets and the No. 2 EGR pipe with the 2 nuts and 2 bolts.

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

  8. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    NOTICE
    DO NOT apply oil to the bolts listed below:
    Tightening Part
    Surge Tank and Intake Manifold
    No. 1 Surge Tank Stay and Surge Tank
    Throttle Body Bracket and Surge Tank

    1. A01NDLR

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

    2. A01NE93E01
      Text in Illustration
      *1 Bolt
      *2 Nut

      Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

      Torque:
      Bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
    3. A01NHZZ

      Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01NCZR

      Connect the connector to the manifold absolute pressure sensor.

    5. A01NGGD

      Connect the ventilation hose.

    6. A01NHMY

      Install the 5 clamps and connect the main wire to the body.

    7. A01NG7C

      Connect the 2 water by-pass hoses to the throttle body assembly.

    8. A01NF4U

      Connect the fuel vapor feed hose.

    9. A01ND1X

      Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.

  9. INSTALL AIR CLEANER ASSEMBLY WITH HOSE


    1. Install the air cleaner assembly with hose Click here.

  10. INSPECT FOR FUEL LEAK


    1. Check fuel pump operation.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the power switch on (IG).

        Note

        Do not start the engine.

      3. Turn the intelligent tester on.

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

      5. 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 power switch off.

    4. Disconnect the intelligent tester from the DLC3.