INTAKE MANIFOLD INSTALLATION

PROCEDURE

  1. INSTALL STUD BOLT

    Tip:

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

    1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  2. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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

  3. INSTALL INTAKE MANIFOLD

    1. for LHD:

      1. Install the hose clamp to the intake manifold.

    2. for RHD:

      1. Install the 2 hose clamps to the intake manifold.

    3. Temporarily install the intake manifold to the cylinder head sub-assembly with the 4 bolts.

    4. A426674N01

      Tighten the 4 bolts in the order shown in the illustration.

      24 N*m

      245 kgf*cm

      18 ft.*lbf

    5. A324768

      for LHD:

      1. 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.

      2. Engage the wire harness clamp.

  4. CONNECT ENGINE WIRE

    1. A426668

      Engage the 2 wire harness clamps.

    2. A426667

      Engage the 3 wire harness clamps and connect the engine wire to the intake manifold.

    3. Connect the wire harness clamp bracket to the intake manifold with the bolt.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

  5. INSTALL CLUTCH CABLE BRACKET (for Manual Transaxle)

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

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  6. 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.

  7. CONNECT VACUUM HOSE ASSEMBLY

    1. for LHD:

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

    2. for RHD:

      1. Engage the vacuum hose assembly to the 2 hose clamps.

    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.

  8. 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.

  9. ENGAGE WATER BY-PASS HOSE ASSEMBLY

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

  10. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

    1. Install 2 new EGR pipe gaskets to the No. 1 EGR pipe sub-assembly and intake manifold.

    2. A423429N01

      Temporarily install the No. 1 EGR pipe sub-assembly with the 2 bolts and 2 nuts.

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

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  11. INSTALL PURGE VALVE (PURGE VSV)

    Click here

  12. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  13. INSTALL OUTER COWL TOP PANEL (for LHD)

    Click here

  14. INSTALL OUTER COWL TOP PANEL (for RHD)

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here