Part 2

Intake Manifold

INSTALLATION

1. Install the intake manifold onto cylinder heads.

NOTE: Use a new gasket.

Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)






2. Connect the fuel delivery hose, fuel return hose, and evaporation hose.






3. Connect the connector (A) to the oil level switch.
4. Connect the connector (B) to ignition coil, and secure the engine harness or oil level switch harness to the rocker cover with clips (C) and bolt (D).

Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






5. Connect the connector to the intake oil flow control solenoid valve.






6. Connect the connector to the intake camshaft position sensor.






7. Connect the connector to the knock sensor.






8. Secure the generator cord to the intake manifold protector LH with a clip.






9. Connect the connector (A) to the front oxygen (A/F) sensor and the connector (B) from to the rear oxygen sensor.






10. Connect the connector (A) to the engine coolant temperature sensor, connector (B) to the oil pressure switch, and the connector (C) to the crankshaft position sensor.






11. Install the engine harness connector to the engine rear hanger.






12. Connect the bulkhead harness connector to the engine harness connector (black), and install the bolt securing the bulkhead harness connector bracket.

Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






13. Connect the bulkhead harness connector to the engine harness connector (brown).






14. Install the PCV pipe to the intake manifold protector RH, and connect vacuum control hose (A) to the PCV pipe.

Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






15. Install the blow-by pipe to the PCV pipe, and connect vacuum hose to the blow-by pipe.

Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






16. Connect the vacuum hose to PCV valve.






17. Connect the preheater hose to the throttle body, and connect the connector to the throttle position sensor.






18. Install the intake duct to the throttle body.

NOTE: When installing the intake duct to the throttle body, align the protrusion (a) on the intake duct to the installation position mark (b) on the throttle body to install.






Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)






19. Install the bolts which secure the engine harness and PCV pipe to the intake manifold, and install the brake booster vacuum hose to the clip (A).

Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)






20. Connect the brake booster vacuum hose.






21. Install the A/C pressure hoses to A/C compressor.
22. Install the intercooler.
23. Install the air intake duct.
24. Lift up the vehicle.
25. Connect the connectors to the wastegate control solenoid valve, and secure the engine harness with clip (A).






26. Connect the connector (A) to the exhaust camshaft position sensor and the connector (B) to the exhaust oil flow control solenoid valve.






27. Install the under cover.
28. Lower the vehicle.
29. Connect the battery ground terminal.






30. Fill engine coolant.
31. Charge the A/C system with refrigerant.
32. Install the collector cover.

INSPECTION

1. Check that the intake manifold and fuel pipe have no deformation, cracks and other damages.
2. Check that the hose has no cracks, damage or loose part.