Install Intake Manifold

INSTALL INTAKE MANIFOLD (VEHICLES WITH SAI)

1. Clean the upper and lower intake manifold mating faces, dowels and dowel holes.

2. Using a new gasket, position the upper intake manifold. Install the bolts and, working in a diagonal sequence, tighten to 22 Nm (16 lbf-ft).

3. Connect the IACV hose and secure with the clip.

4. Connect the hose to the air valve and tighten the clip.

5. Secure the spark plug leads to the retaining clips.

6. Install and tighten the nuts securing the right-hand air manifold support bracket.

7. Align the air pipe and coil mounting bracket, install the bolts and tighten to 8 Nm (6 lbf-ft).

8. Tighten the two lower bolts securing the coil mounting bracket and tighten to 8 Nm (6 lbf-ft).

9. Secure engine harness in the bulkhead clips.

10. Connect the breather hose to the manifold and secure with the clip.

11. Connect the vacuum hose to the intake manifold.

12. Connect the brake servo hose to the intake manifold.

13. Connect the throttle and cruise control cables.

14. Adjust the throttle cable.

15. Adjust the cruise control cable.

16. Connect the coolant hoses to the throttle housing and secure with clips.

17. Connect the connector to throttle position sensor.

18. Connect the breather hose to the throttle housing and secure with clip.

19. Connect the connector to the IACV.

20. Secure the purge valve and the air control valve to the retaining clips and bracket.

21. Connect the purge hose to the manifold.

NOTE:
The union nuts should be started but NOT tightened in the next step. The air manifold support bracket nuts must be tightened before the union nuts.

22. Clean the air manifold unions, position the manifold and start the union nuts.

23. Install and tighten the nuts securing the air manifold support bracket.

24. Tighten the air manifold union nuts to 25Nm (18 lbf-ft)

25. Using a new O-ring, install the coolant pipe inlet tube to the intake manifold and tighten the bolts to 14 Nm (10 lbf-ft).

26. Install the bolt securing the coolant pipe outlet tube to the cylinder block and tighten bolts to 14Nm (10 lbf-ft).

27. Connect the hose to the air valve and tighten the clip.

28. Connect the vacuum hose to the air valve.

29. Install the air intake hose.

30. Connect the connector to the MAF sensor.

31. Secure the wiring harness to retaining clip.

32. Connect the battery ground lead.

33. Install the battery cover.

34. Top up the cooling system as necessary.

35. Remove the container from beneath the vehicle.