Removal and Installation
INTAKE MANIFOLDREMOVAL AND INSTALLATION [2.4L ENGINE]
Pre-removal & Post-installation Operation:
Removal Steps 1-21:
REMOVAL SERVICE POINT
[[A]] RADIATOR LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.
INSTALLATION SERVICE POINTS
]]A[[ THERMOSTAT CASE ASSEMBLY INSTALLATION
1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface.
2. Apply a bead of the sealant to the cylinder head mating surface of the thermostat case assembly as shown.
Specified Sealant: 3M(TM) AAD Part No.8672, 3M(TM) AAD part No.8679/8678 or equivalent
NOTE: Install the thermostat case assembly immediately after applying sealant.
3. Apply sealant to the thread of the thermostat case assembly mounting bolt as shown.
Specified Sealant: 3M(TM) AAD Part No.8730, 8731 or equivalent
NOTE: Install the thermostat case assembly mounting bolt immediately after applying sealant.
CAUTION: After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
4. Tighten the thermostat case assembly mounting bolts to the specified torque.
Tightening torque: 24 ± 4 N.m (18 ± 3 ft-lb)
]]B[[ RADIATOR LOWER HOSE CONNECTION
1. Insert each hose as far as the projection of the water inlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.
]]C[[ BRAKE BOOSTER VACUUM HOSE CONNECTION
Insert vacuum hose with its paint mark facing upward.
]]D[[ EGR VALVE GASKET INSTALLATION
Install the EGR valve gasket as shown in the illustration.