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 Tumble Generator Valve Assembly Bolts
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Connect the fuel delivery hose, fuel return hose, and evaporation hose.
NOTE: If fuel hoses or clamps are damaged, replace them with new parts.

Fig 2: Identifying Fuel Delivery, Fuel Return And Evaporation Hoses
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Connect the connector to the front oxygen (A/F) sensor, and secure the engine harness to rocker cover RH with the clip (A) and stay (B).
Tightening torque:

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

Fig 3: Locating Front Oxygen (A/F) Sensor Connector
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Connect the connector to the ignition coil.

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5. Connect the air duct to the secondary air pump, and install the air duct on the rocker cover LH.
Tightening torque:

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

Fig 4: Locating Air Duct Clamp And Bolt
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Connect the connector to the oil flow control solenoid valve.

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Connect the connectors to camshaft position sensor.

Fig 5: Identifying Oil Flow Control Solenoid Valve Connector
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Connect the connector to the secondary air combination valve.

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Connect the connector to the knock sensor.

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Connect the connector to the power steering pump switch.

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

Fig 6: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor
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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 7: Locating Bulkhead Harness Connectors From Engine Harness Connectors
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Connect the air control hose (A) to wastegate actuator, and install the turbocharger to the intake duct.
Tightening torque:

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

Fig 8: Identifying Air Control Hose With Bolt
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Connect the PCV hose to the rocker cover.
NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp.

ST 18353AA000 CLAMP PLIERS

Fig 9: Identifying PCV Hose Clamp
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Connect the brake booster vacuum hose.

Fig 10: Locating Brake Booster Vacuum Hose And Clamp
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Connect the engine coolant hoses to throttle body.

Fig 11: Identifying Engine Coolant Hoses
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Install the duct to the throttle body.
Tightening torque:

3 N.m (0.3 kgf-m, 2.2 ft-lb)
Attach the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold.
Tightening torque:

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

Fig 12: Locating Air By-Pass Pipe Bolts
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Attach the connector to the PCV hose assembly.

Fig 13: Identifying PCV Hose Assembly Connector
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Connect the vacuum hose (A) and the connector (B) to the PCV hose assembly.

Fig 14: Identifying Vacuum Hose And Connector
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Install the A/C pressure hoses. Refer to INSTALLATION , Hose and Pipe.
Install the coolant filler tank. Refer to INSTALLATION , Coolant Filler Tank.
Install the generator. Refer to INSTALLATION , Generator.
Install the intercooler. Refer to INSTALLATION , Intercooler.
Install the air intake boot. Refer to INSTALLATION , Air Intake Duct.
Tightening torque:

2.5 N.m (0.3 kgf-m, 1.8 ft-lb)
Install the air intake duct (rear). Ref. to INSTALLATION .
Connect the ground cable to battery.

Fig 15: Disconnecting Ground Cable From Battery
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Lift up the vehicle.
Install the under cover.
Lower the vehicle.
Fill engine coolant. Refer to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.
Charge the A/C system with refrigerant. Refer to PROCEDURE , Refrigerant Charging Procedure.
Install the collector cover.