Intake Manifold: Installation

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)

Fig 1: Locating Intake Manifold
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Connect the fuel delivery hose, fuel return hose, and evaporation hose.

Fig 2: Identifying Fuel Delivery Hose, Fuel Return Hose And Evaporation Hose
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Fix the engine harness to the rocker cover LH with the air duct.
Tightening torque: 9 N.m (0.9 kgf-m, 6.6 ft-lb)

Fig 3: Locating Air Duct To Rocker Cover LH And Bolts
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Fix the engine harness to the rocker cover RH with clips (A).

Fig 4: Identifying Engine Harness To Rocker Cover RH With Clips
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Lift up the vehicle.
Connect the connectors to the exhaust camshaft position sensor (A), exhaust oil flow control solenoid valve (B), and ignition coil (C).

Fig 5: Identifying Exhaust Camshaft Position Sensor, Exhaust Oil Flow Control Solenoid Valve And Ignition Coil Connectors
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Install the engine harness cover, (right side only.)
Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)

Fig 6: Identifying Engine Harness Cover And Bolt
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Lower the vehicle.
Connect the connector to the intake oil flow control solenoid valve.

Fig 7: Locating Intake Oil Flow Control Solenoid Valve Connector
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Connect the connector to the intake camshaft position sensor.

Fig 8: Locating Intake Camshaft Position Sensor Connector
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Connect the connector to the secondary air combination valve.

Fig 9: Locating Secondary Air Combination Valve Connector
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Connect the connector to the knock sensor.

Fig 10: Locating Knock Sensor Connector
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Connect the connector to the power steering pump switch.

Fig 11: Identifying Power Steering Pump Switch Connector
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Connect the connector to the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).

Fig 12: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor Connectors
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Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.

Fig 13: Identifying Engine Harness Connectors
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Connect the air control hose (A) to the waste-gate actuator, and install the turbocharger to the intake duct.
Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)

Fig 14: Locating Air Control Hose
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Connect the brake booster vacuum hose (A) and pressure regulator vacuum hose (B) to the intake manifold.

Fig 15: Identifying Brake Booster Vacuum Hose And Pressure Regulator Vacuum Hose
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Connect the engine coolant hoses to throttle body.

Fig 16: Locating Engine Coolant Hose
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Connect the vacuum hose (A) to the PCV hose assembly and the PCV hose assembly connector (B) to the intake duct.

Fig 17: Identifying Vacuum Hose
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Install the A/C pressure hoses to A/C compressor. Ref. to INSTALLATION , Hose and Pipe.
Install the coolant filler tank. Ref. to INSTALLATION , Coolant Filler Tank.
Install the generator. Ref. to INSTALLATION , Generator.
Install the intercooler. Ref. to INSTALLATION , Intercooler.
Install the air intake boot.
Tightening torque: 2.5 N.m (0.3 kgf-m, 1.8 ft-lb)

Fig 18: Locating Air Intake Boot
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Install the air intake duct. Ref. to INSTALLATION , Air Intake Duct.
Connect the ground cable to battery.

Fig 19: Identifying Battery Ground Cable
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Lift up the vehicle.
Install the under cover.
Lower the vehicle.
Install the V-belt cover.
Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)

Fig 20: Locating V-Belt Covers
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Fill engine coolant. Ref. to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.
Charge the A/C system with refrigerant. Ref. to PROCEDURE , Refrigerant Charging Procedure.