INTAKE MANIFOLD INSTALLATION

PROCEDURE

  1. INSTALL EGR VALVE ASSEMBLY

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  2. TEMPORARILY INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

    1. Install a new No. 2 intake manifold to head gasket to the cylinder head sub-assembly.

    2. Temporarily install the No. 1 intake manifold insulator to the EGR valve with the 2 bolts and nut.

  3. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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

  4. INSTALL INTAKE MANIFOLD (for LHD)

    1. Temporarily install the intake manifold to the cylinder head sub-assembly with the 2 bolts and 2 nuts.

    2. A323405C01
      V100135

      Bolt
      V100136

      Nut

      Tighten the 4 bolts and 3 nuts in the order shown in the illustration.

      30 N*m

      306 kgf*cm

      22 ft.*lbf

    3. Engage the 2 wire harness clamps to the intake manifold.

    4. A324768

      Connect the ECM connector and lower the lever.

      Note:

      • When connecting the ECM connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the ECM connector.

      • Be sure to securely connect the ECM connector.

    5. Engage the wire harness clamp.

  5. SET INTAKE MANIFOLD (for RHD)

    1. Set the intake manifold.

  6. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for RHD)

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  7. INSTALL INTAKE MANIFOLD (for RHD)

    1. Temporarily install the intake manifold with the 2 bolts and 2 nuts.

    2. A323405C01
      V100135

      Bolt
      V100136

      Nut

      Tighten the 4 bolts and 3 nuts in the order shown in the illustration.

      30 N*m

      306 kgf*cm

      22 ft.*lbf

    3. Engage the 2 wire harness clamps to the intake manifold.

  8. INSTALL WIRE HARNESS CLAMP BRACKET

    1. Install the wire harness clamp bracket to the cylinder head sub-assembly with the bolt.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

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

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    3. Engage the 3 wire harness clamps.

  9. INSTALL FUEL HOSE BRACKET

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

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    2. Engage the fuel tube sub-assembly to the hose clamp.

  10. ENGAGE WATER BY-PASS HOSE ASSEMBLY

    1. Engage the water by-pass hose assembly to the 4 hose clamps.

  11. INSTALL CLUTCH CABLE BRACKET

    1. Install the clutch cable bracket with the 2 nuts.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  12. CONNECT VACUUM HOSE ASSEMBLY

    1. Engage the vacuum hose assembly to the hose clamp. (for RHD)

    2. Engage the vacuum hose assembly to the hose clamp.

    3. Align the vacuum hose assembly connector with the intake manifold, and push them together until the vacuum hose assembly connector makes a "click" sound.

  13. CONNECT NO. 2 FUEL VAPOR FEED HOSE

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

  14. INSTALL VACUUM SENSOR ASSEMBLY

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  15. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  16. INSTALL OUTER COWL TOP PANEL (for LHD)

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  17. INSTALL OUTER COWL TOP PANEL (for RHD)

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  18. INSTALL FRONT AIR SHUTTER SEAL RH (for LHD)

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  19. INSTALL FRONT AIR SHUTTER SEAL RH (for RHD)

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  20. INSTALL FRONT NO. 1 VENTILATOR SEAL (for LHD)

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  21. INSTALL FRONT NO. 1 VENTILATOR SEAL (for RHD)

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  22. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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