INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL VACUUM SURGE TANK


    1. Install the vacuum surge tank to the intake manifold with the 3 bolts.

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

  2. INSTALL NO. 4 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. Install the No. 4 vacuum transmitting hose assembly to the intake manifold and vacuum surge tank.

  3. INSTALL VACUUM REGULATING VALVE ASSEMBLY


    1. Install the vacuum regulating valve assembly to the intake manifold with the 2 bolts.

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

    2. Connect the vacuum regulating valve assembly connector.

  4. INSTALL NO. 3 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. Install the No. 3 vacuum transmitting hose assembly to the vacuum surge tank and vacuum regulating valve assembly.

    2. Engage the No. 3 vacuum transmitting hose assembly to the intake manifold.

  5. INSTALL BRACKET


    1. Install the bracket to the intake manifold with the bolt.

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

  6. INSTALL NO. 2 FUEL VAPOR FEED HOSE


    1. Install the No. 2 fuel vapor feed hose to the intake manifold and slide the clip to secure it.

  7. INSTALL INTAKE MANIFOLD


    1. When installing a new intercooler support bracket sub-assembly:

      Temporarily install the intake manifold.

      Note

      If temporary installation is not performed, connecting parts may not be airtight as a result of incorrect positioning.


      1. B008052

        Temporarily install a new intercooler support bracket sub-assembly to the intake manifold with the 2 bolts.

      2. Temporarily install the intercooler assembly.

        Click here

      3. Tighten the 2 bolts of the intercooler support bracket sub-assembly.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      4. B007XF5

        Remove the 2 bolts and intercooler assembly from the intercooler support bracket sub-assembly.

    2. When reusing the intercooler support bracket sub-assembly:

      Align the matchmarks and install the intercooler support bracket sub-assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B007YIUC01
      *a Correct
      *b Incorrect
      *c Stopper

      Install the manifold thermostat to the intercooler support bracket sub-assembly with the 2 nuts.

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

      Note

      Make sure that the manifold thermostat does not contact the stopper as shown in the illustration.

    4. Install 2 new No. 1 intake manifold to head gaskets to the intake manifold.

    5. Temporarily install the intake manifold with the 3 bolts and 2 nuts.

    6. B007Z7DC02
      B007WXX Bolt
      B00803L Nut

      Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    7. B007XZD

      Connect the intercooler support bracket sub-assembly to the cylinder block sub-assembly with the bolt.

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

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

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

  8. CONNECT WATER BY-PASS HOSE


    1. Connect the No. 1 water by-pass hose to the cylinder head sub-assembly and slide the clip to secure it.

    2. Connect the No. 2 water by-pass hose to the No. 1 water by-pass pipe and slide the clip to secure it.

  9. INSTALL NO. 2 VENTILATION HOSE


    1. Install the No. 2 ventilation hose to the intake manifold and PCV valve (ventilation valve sub-assembly) and slide the 2 clips to secure it.

  10. CONNECT VACUUM TRANSMITTING HOSE ASSEMBLY


    1. Connect the vacuum transmitting hose assembly to the vacuum regulating valve assembly.

  11. INSTALL NO. 1 TURBO PRESSURE SENSOR

    Click here

  12. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. Connect the No. 2 vacuum transmitting hose assembly to the vacuum pump assembly and cylinder head cover sub-assembly.

  13. INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install the No. 2 water by-pass pipe to the cylinder head cover sub-assembly and bracket with the 3 bolts.

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

  14. CONNECT ENGINE WIRE


    1. B007XGYC01
      B007WXX Bolt
      B00803L Connector
      B007X40 Ground Bolt

      Install the bolt.

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

    2. Install the ground bolt.

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

    3. Engage the 4 wire harness clamps.

    4. Connect the 5 connectors.

    5. B007ZI1C01
      B007WXX Bolt
      B00803L Connector

      Install the bolt.

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

    6. Engage the 4 wire harness clamps.

    7. Connect the 7 connectors.

    8. B007X18

      Connect the sensor wire to the intercooler support bracket sub-assembly.

    9. Install the sensor wire to the intercooler support bracket sub-assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    10. B007XG6C01
      B007WXX Bolt
      B00803L Connector

      Install the 2 bolts to the wire harness bracket.

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

    11. Engage the wire harness clamp from the wire harness bracket.

    12. Connect the 3 sensor wire connectors.

  15. CONNECT NO. 6 INTERCOOLER COOLING WATER HOSE


    1. B007XSMC01
      *a Up
      *b RH
      *c 90°
      *d Paint Mark
      *e Matchmark

      Connect the No. 6 intercooler cooling water hose to the No. 2 Intercooler cooling water pipe and slide the clip to secure it.

      Tech Tips


      • Engage the clip within the area shown in the illustration.

      • Make sure that the paint mark of the No. 6 intercooler cooling water hose is positioned as shown in the illustration.

  16. CONNECT NO. 5 INTERCOOLER COOLING WATER HOSE


    1. B007X3SC01
      *a Up
      *b RH
      *c 90°
      *d Paint Mark
      *e Matchmark

      Connect the No. 5 intercooler cooling water hose to the No. 3 Intercooler cooling water pipe and slide the clip to secure it.

      Tech Tips


      • Engage the clip within the area shown in the illustration.

      • Make sure that the paint mark of the No. 5 intercooler cooling water hose is positioned as shown in the illustration.

  17. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. B007Y0GC02
      *a Air Cleaner Support
      *b Protrusion

      Fit the protrusion of the air cleaner case sub-assembly into the air cleaner support as shown in the illustration.

    2. Install the air cleaner case sub-assembly with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  18. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

  19. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  20. INSTALL PURGE VALVE (PURGE VSV)

    Click here

  21. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  22. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  23. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  24. INSTALL INTERCOOLER ASSEMBLY

    Click here

  25. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here