INSTALLATION

PROCEDURE

1. INSTALL STUD BOLT (w/ Stud Bolt)

HINT:

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

(a) Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

2. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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

3. INSTALL INTAKE MANIFOLD

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

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

Torque:

28 N·m {286 kgf·cm, 21 ft·lbf}

	Bolt
	Nut

4. CONNECT WATER BY-PASS HOSE

(a) Engage the 2 hose clamps to connect the No. 2 water by-pass hose to the intake manifold.

*1 Water By-Pass Hose *2 No. 2 Water By-pass Hose

(b) Engage the 2 hose clamps to connect the water by-pass hose to the intake manifold.

5. CONNECT NO. 2 FUEL VAPOR FEED HOSE

(a) Engage the 2 hose clamps.

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

6. CONNECT NO. 8 WATER BY-PASS HOSE

(a) Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.

(b) Engage the 2 hose clamps.

7. CONNECT ENGINE COVER BRACKET

(a) Connect the engine cover bracket to the intake manifold with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

8. CONNECT ENGINE WIRE

(a) Engage the clamp and connect the engine wire with the bolt. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf}

(b) Connect the 4 fuel injector assembly connectors and purge valve (purge VSV) connector.

(c) Connect the wire harness bracket with the bolt. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf}

(d) Connect the engine water pump assembly connector.

(e) Engage the 2 clamps.

9. CONNECT VENTILATION HOSE

(a) Connect the ventilation hose to the intake manifold and slide the clip to secure it.

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

(a) Install the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) to the intake manifold with the bolt.

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

(b) Connect the vacuum hose to the intake manifold.

(c) Connect the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) connector.

11. INSTALL EGR PIPE ASSEMBLY

(a) Install a new EGR pipe gasket to the EGR valve assembly. NOTICE: Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

*a Claw

(b) Install a new inlet EGR gasket to the intake manifold. HINT: Align the protrusion of the inlet EGR gasket with the groove of the intake manifold.

*a Groove *b Protrusion

(c) Install the EGR pipe assembly to the intake manifold and EGR valve assembly with the 4 bolts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

12. INSTALL INLET NO. 1 AIR CLEANER

(a) Install the inlet No. 1 air cleaner to the intake manifold with the 2 bolts.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

13. INSTALL AIR CLEANER BRACKET

(a) Engage the wire harness clamp and install the air cleaner bracket to the cylinder block sub-assembly and air conditioning wire with the bolt (A) and 2 bolts (B). Torque: Bolt (A) : 12.5 N·m {127 kgf·cm, 9 ft·lbf} Bolt (B) : 12 N·m {122 kgf·cm, 9 ft·lbf}

*a Bolt (A) *b Bolt (B)

14. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case sub-assembly to the air cleaner bracket with the 2 bolts.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

15. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

(a) Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

16. INSTALL INLET NO. 2 AIR CLEANER

(a) Temporarily install the inlet No. 2 air cleaner to the inlet No. 1 air cleaner and upper radiator support sub-assembly with the 2 bolts. HINT: Align the protrusion of the inlet No. 1 air cleaner with the groove of the inlet No. 2 air cleaner.

*a Groove *b Protrusion

(b) Tighten the 2 bolts.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(c) Tighten the hose clamp.

Torque:

2.0 N·m {20 kgf·cm, 18 in·lbf}

(d) Install the clip.

17. INSTALL RADIATOR SUPPORT OPENING COVER

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18. INSTALL THROTTLE BODY ASSEMBLY

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