RM38T0EC _51 Engine / Hybrid System _144997 M20F-FXS, M20G-FXS INTAKE / EXHAUST _0604322 INTAKE MANIFOLD A

M20F-FXS, M20G-FXS INTAKE / EXHAUST  INTAKE MANIFOLD  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A528021N04
0.083,1.167 0.771,1.333 0.688,0.167 2.813,2.167 3.5,2.333 0.688,0.167 4,5.25 4.688,5.417 0.688,0.167 3.708,5.615 4.396,5.781 0.688,0.167 0.542,4.938 1.229,5.104 0.688,0.167 3.531,3.531 4.219,3.698 0.688,0.167 0.063,3.104 1.01,3.271 0.948,0.167 0.99,2.823 1.677,2.99 0.688,0.167 1.625,0.229 2.635,0.396 1.01,0.167 4.313,0.198 4.958,0.365 0.646,0.167 0.75,3.625 1.354,3.792 0.604,0.167 2.396,1.052 2.906,1.052 false 5.698,1.906 5.865,1.906 5.865,1.906 6.24,1.625 false 4.219,1.51 3.979,1.906 3.979,1.906 3.74,1.906 false 3.844,2.729 4.219,2.729 false 5.302,2.833 5.698,2.833 false 4.771,2.531 5.156,2.531 false 1.646,3.677 1.771,3.448 1.771,3.448 1.938,3.448 false 1.323,1.667 1.677,1.667 false 6.031,2.271 6.427,2.271 false 1.615,4.51 1.615,4.094 false 1.51,5.125 1.708,5.125 1.708,5.125 2.052,5.438 false 1.271,5.615 1.5,5.615 false 2.729,3.958 3.177,3.208 3.177,3.208 3.385,3.208 false 4.885,1.771 4.885,1.469 false 0.938,4.531 0.938,4.323 false 3.333,5.344 3.604,4.802 3.604,4.802 3.771,4.802 false 0.25,1.167 0.25,0.375 0.25,0.375 0.531,0.375 false 0.25,0.688 0.438,0.688 false 3.5,2.25 3.833,2.25 false 3.75,5.333 4,5.333 false 3.198,5.583 3.521,5.708 3.521,5.708 3.708,5.708 false 0.229,5.021 0.542,5.021 false 3.281,3.615 3.531,3.615 false 1.01,3.188 1.115,3.188 1.115,3.188 1.292,3.396 false 1.688,2.896 1.885,2.896 1.885,2.896 2.125,3.104 false 2.646,0.313 2.76,0.313 2.76,0.313 3.26,0.771 false 4.958,0.281 5.26,0.281 false 0.469,3.917 0.583,3.708 0.583,3.708 0.75,3.708 false 2.104,0.938 2.5,1.313 0.396,0.375 18 false 15 5.396,1.781 5.792,2.156 0.396,0.375 18 false 14 4.792,1.833 5.188,2.208 0.396,0.375 18 false 13 3.25,1.771 3.646,2.146 0.396,0.375 18 false 12 3.542,2.594 3.938,2.969 0.396,0.375 18 false 11 5.938,2.698 6.333,3.073 0.396,0.375 18 false 10 5.406,2.396 5.802,2.771 0.396,0.375 18 false 9 1.979,3.333 2.375,3.708 0.396,0.375 18 false 8 1.333,4.99 1.729,5.365 0.396,0.375 18 false 7 1.729,1.521 2.125,1.896 0.396,0.375 18 false 6 0.865,4.573 1.26,4.948 0.396,0.375 18 false 5 4.063,4.656 4.458,5.031 0.396,0.375 18 false 4 3.719,3.094 4.115,3.469 0.396,0.375 18 false 3 6.646,2.146 7.042,2.521 0.396,0.375 18 false 2 1.469,4.521 1.865,4.896 0.396,0.375 18 false 1 1.552,5.5 1.958,5.802 0.406,0.302 18 false 6 0.333,0.75 0.729,1.125 0.396,0.375 10 false x2 0.156,1.177 0.896,1.417 0.74,0.24 8 false 10 (102, 7) 4,2.208 4.396,2.583 0.396,0.375 10 false x4 2.885,2.188 3.625,2.427 0.74,0.24 8 false 10 (102, 7) 4.073,5.26 4.813,5.5 0.74,0.24 8 false 10 (102, 7) 3.75,5.625 4.469,5.823 0.719,0.198 8 false 21 (214, 15) 0.594,4.958 1.333,5.198 0.74,0.24 8 false 10 (102, 7) 3.292,3.729 3.688,4.104 0.396,0.375 10 false x4 3.583,3.542 4.302,3.74 0.719,0.198 8 false 24 (245, 18) 0.094,3.115 1.167,3.396 1.073,0.281 8 false 5.0 (51, 44 in.*lbf) 2.25,3.063 2.646,3.438 0.396,0.375 10 false x2 1.042,2.833 2.115,3.115 1.073,0.281 8 false 24 (245, 18) 1.688,0.24 2.969,0.583 1.281,0.344 8 false 4.0 (41, 35 in.*lbf) 4.375,0.208 5.115,0.448 0.74,0.24 8 false 10 (102, 7) 0.771,3.625 1.51,3.865 0.74,0.24 8 false 10 (102, 7) 6.49,2.177 6.885,2.552 0.396,0.375 10 false ● 5.792,2.75 6.188,3.125 0.396,0.375 10 false ● 5.229,2.427 5.625,2.802 0.396,0.375 10 false ● 3.594,1.813 3.99,2.188 0.396,0.375 10 false ● 3.365,0.823 3.76,1.198 0.396,0.375 10 false x3 5.354,0.281 5.75,0.656 0.396,0.375 10 false x3

Procedure Part Name Code
Z101186

Z101188

Z101187

1 VACUUM HOSE - - - -
2 NO. 1 INTAKE MANIFOLD TO HEAD GASKET 17177 - - -
3 INTAKE MANIFOLD 17111 (Click here) - -
4 INTAKE MANIFOLD STAY 17138B (Click here) - -
5 NO. 2 WATER BY-PASS PIPE 16278 (Click here) - -
6 ENGINE WIRE 82121 - - -
7 NO. 1 FUEL VAPOR FEED HOSE 23826 - - -
8 E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR) 89421 - - -
9 EGR INLET GASKET 25628 - - -
10 EGR VALVE ADAPTER GASKET 25629 - - -
11 NO. 1 EGR PIPE SUB-ASSEMBLY 25601 (Click here) - -
12 THROTTLE BODY GASKET 22271 - - -
13 THROTTLE BODY WITH MOTOR ASSEMBLY 22030 (Click here) - -
14 AIR CLEANER CAP WITH AIR CLEANER HOSE - - - -
15 INLET NO. 1 AIR CLEANER 17751 - - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


PROCEDURE

Hide 1.INSTALL VACUUM HOSE

Hide 17177 2.INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Hide 17111 3.INSTALL INTAKE MANIFOLD

a.
A523491N01
0.583,0.094 0.865,0.448 0.281,0.354 18 false i 2.458,0.49 2.667,0.771 0.208,0.281 18 true ii 3.323,0.052 3.563,0.344 0.24,0.292 18 true iii 3.667,0.938 3.823,1.135 0.156,0.198 10 true 1 2.792,0.406 2.948,0.604 0.156,0.198 10 true 2 4.094,0.229 4.25,0.427 0.156,0.198 10 true 3 2.531,0.885 2.688,1.083 0.156,0.198 10 true 4 4.448,0.854 4.604,1.052 0.156,0.198 10 true 5

i.

Temporarily install the intake manifold and No. 2 fuel delivery guard to the cylinder head sub-assembly with the 4 bolts and 2 nuts.


ii.

Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

Torque:
24 N*m (245 kgf*cm, 18 ft.*lbf)


iii.

Tighten the bolt.

Torque:
24 N*m (245 kgf*cm, 18 ft.*lbf)



Hide 17138B 4.INSTALL INTAKE MANIFOLD STAY

a.
A525264N02
2.594,0.792 2.771,1.073 0.177,0.281 18 true i 3.125,1.167 3.354,1.458 0.229,0.292 18 true iii 3.99,0.438 4.219,0.729 0.229,0.292 18 true ii 4.26,0.51 4.469,0.729 0.208,0.219 10 true B 3.385,1.188 3.594,1.406 0.208,0.219 10 true A

i.

Engage the guide to install the intake manifold stay.


ii.

Install the bolt (B).

Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)


iii.

Using an 8 mm socket wrench, install the bolt (A).

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 16278 5.CONNECT NO. 2 WATER BY-PASS PIPE

a.
A525263N01
0.469,0.125 0.75,0.479 0.281,0.354 18 false i

i.

Using an 8 mm socket wrench, connect the No. 2 water by-pass pipe to the intake manifold with the bolt.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 82121 6.CONNECT ENGINE WIRE

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

Hide 23826 7.INSTALL NO. 1 FUEL VAPOR FEED HOSE

Hide 89421 8.INSTALL E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (EMISSION CONTROL)>VACUUM SENSOR>INSTALLATION

Hide 25601 11.INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

Z101186

Click here(Click here)

Hide 22030 13.INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

a.
A483466N01
3.958,0.021 4.094,0.313 0.135,0.292 18 true i 2.479,1.469 2.667,1.75 0.188,0.281 18 true ii

i.

Using an 8 mm socket wrench, install the throttle body with motor assembly to the intake manifold with the 3 bolts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)


ii.

Connect the throttle body with motor assembly connector.