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. 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}

(e) Attach the wire harness clamp to connect the HV air conditioning wire.

7. 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.

8. CONNECT ENGINE WIRE

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

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Connect the engine wire to the cylinder head sub-assembly with the bolt. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Connect the No. 5 engine wire connector.

9. INSTALL PURGE VALVE (PURGE VSV)

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

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11. INSTALL EGR VALVE ASSEMBLY

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12. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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