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 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) Set the intake manifold.

HINT:

At this time, do not install the parts with bolts or nuts.

(b) Connect the fuel pressure sensor connector.

(c) 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}

(d) w/ Stud Bolt:

(1) Temporarily install the intake manifold to the cylinder head sub-assembly.

(2) Using an E8 "TORX" socket wrench, install the 2 stud bolts.

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

(3) Temporarily install the 3 bolts and 2 nuts.

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

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

4. CONNECT NO. 1 FUEL VAPOR FEED HOSE

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

5. INSTALL INTAKE MANIFOLD STAY

(a) Engage the guide to install the intake manifold stay.

(b) Install the bolt (B).

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(c) Using an 8 mm socket wrench, install the bolt (A).

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

6. CONNECT NO. 3 WATER BY-PASS PIPE

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

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

7. CONNECT ENGINE WIRE

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

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Engage the 2 wire harness clamps to connect the engine wire.

(d) Install the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Connect the connector.

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

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9. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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10. INSTALL THROTTLE BODY GASKET

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11. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

(a) Using an 8 mm socket wrench, install the throttle body with motor assembly to the intake manifold with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Connect the throttle body with motor assembly connector.

12. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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13. INSTALL INLET NO. 1 AIR CLEANER

14. INSTALL RADIATOR SUPPORT OPENING COVER