INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL VACUUM HOSE

(a) Install the vacuum hose to the intake manifold.

2. INSTALL NO. 1 ENGINE COVER

(a) Install the No. 1 engine cover with the clip.

3. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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

4. INSTALL INTAKE MANIFOLD

(a) w/o Stud Bolt: (1) Temporarily install the intake manifold to the cylinder head sub-assembly with the 5 bolts. (2) Tighten the 5 bolts in the order shown in the illustration. Torque: 24 N·m {245 kgf·cm, 18 ft·lbf}

(b) w/ Stud Bolt:

	Bolt
	Nut

(1) Temporarily install the intake manifold to the cylinder head sub-assembly with the 3 bolts and 2 nuts.

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

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

5. CONNECT NO. 2 FUEL VAPOR FEED HOSE

(a) Connect the No. 2 fuel vapor feed hose to the intake manifold.

6. CONNECT NO. 3 WATER BY-PASS PIPE

(a) Using an 8 mm socket wrench, connect the No. 3 water by-pass pipe to the intake manifold with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.

7. INSTALL NO. 2 WATER BY-PASS PIPE

(a) Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (B).

(b) Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (A).

(c) Tighten the bolt (B).

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Using the 8 mm socket wrench, tighten the 2 bolts (A).

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

8. CONNECT ENGINE WIRE

(a) Attach the wire harness clamp to connect the engine wire.

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

9. INSTALL E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)

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10. INSTALL EGR VALVE ASSEMBLY

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11. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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