INTAKE MANIFOLD INSTALLATION

PROCEDURE

  1. INSTALL INTAKE FLANGE (w/o EGR System)

    1. Install a new gasket to the intake manifold.

    2. Install the intake flange with the 3 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    3. Install the engine cover joint to the intake flange.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  2. INSTALL INTAKE MANIFOLD

    1. A331879C02

      *a

      Top

      *b

      Rear

      Connect the purge line hose to the intake manifold, and slide the clamp to secure the hose.

      Tip:

      Make sure the hose clamp is oriented as shown in the illustration.

    2. Install the vacuum hose to the intake manifold.

    3. Install the wiring harness clamp bracket with the bolt.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

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

    5. Install the intake manifold to the vehicle.

  3. INSTALL FUEL DELIVERY PIPE

    Click here

  4. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  5. CONNECT NO. 1 EGR PIPE (w/ EGR System)

    1. Install a new gasket to the No. 1 EGR pipe.

      Note:

      Make sure the claws of the gasket face the No. 1 EGR pipe.

    2. Temporarily install the No. 1 EGR pipe with the 3 bolts and nut.

    3. Tighten the 3 bolts and nut to connect the No. 1 EGR pipe.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  6. CONNECT INTAKE MANIFOLD

    1. Temporarily install the intake manifold with the 6 bolts.

    2. A282983

      Tighten the 6 bolts in the order shown in the illustration.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    3. Connect the No. 2 PCV hose to the intake manifold, and slide the clamp to secure the hose.

  7. CONNECT ENGINE WIRE

    1. Attach the 6 clamps and connect the engine wire.

    2. Connect the heated oxygen sensor connector.

  8. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR

    Click here

  9. INSTALL EGR VALVE ASSEMBLY (w/ EGR System)

    Click here

  10. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  11. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  12. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    1. for LHD:

      1. Install the outer cowl top panel sub-assembly with the 13 bolts.

        5.5 N*m

        56 kgf*cm

        49 in.*lbf

      2. Attach the 4 clamps and connect the wire harness.

      3. Connect the connector.

    2. for RHD:

      1. Install the outer cowl top panel sub-assembly with the 13 bolts.

        5.5 N*m

        56 kgf*cm

        49 in.*lbf

      2. Attach the 2 clamps and connect the wire harness.

  13. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

  14. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  15. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note:

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

    Click hereClick hereClick here

  16. INSTALL BATTERY SERVICE COVER

    Click here

  17. INSTALL DECK BOARD ASSEMBLY

    Click here

  18. ADD ENGINE COOLANT

    Click here

  19. INSPECT FOR COOLANT LEAK

    Click here

  20. INSPECT FOR FUEL LEAK