RM35X0E _51 Engine / Hybrid System _079308 7GR-FKS INTAKE / EXHAUST _0385725 INTAKE MANIFOLD A

7GR-FKS INTAKE / EXHAUST INTAKE MANIFOLD INSTALLATION

PROCEDURE

Hide Display 17111 1.INSTALL INTAKE MANIFOLD

Set 2 new No. 1 intake manifold to head gaskets on each cylinder head as shown in the illustration.

NOTICE:: ·

Align the port holes of the gasket and cylinder head sub-assembly and cylinder head LH.

·

Be careful of the installation direction.

Set the intake manifold on the cylinder head sub-assembly and cylinder head LH.

Install and uniformly tighten the 4 bolts and 4 nuts.

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

Hide Display 23800 2.INSTALL FUEL DELIVERY WITH SENSOR PIPE ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (FUEL)>FUEL INJECTOR (for Port Injection)>INSTALLATION201902,999999,_51,_079024,_0383259,RM100000001G9W4_01_0049,

Hide Display 17190 3.INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTICE:

Do not apply oil to the bolts and nuts as listed below:

Oil Application Prohibited Bolt and Nut
Bolt and Nut for Intake Air Surge Tank Assembly and Intake Manifold

Install a new air surge tank to intake manifold gasket to the intake air surge tank assembly.

Set the intake air surge tank assembly on the intake manifold.

Install and uniformly tighten the 5 bolts and 2 nuts.

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

Connect the PCV hose to the intake air surge tank assembly, and slide the clamp to secure the hose.

Connect the intake air control valve actuator connector to the intake air control valve actuator.

Install the 2 bolts to connect the engine wire to the intake air surge tank assembly.

Torque:: 13 N*m (133 kgf*cm, 10 ft.*lbf)

Attach the clamp to connect the No. 1 fuel pipe sub-assembly and No. 2 fuel pipe sub-assembly.

Connect the fuel vapor feed hose to the purge VSV, and slide the clamp to secure the hose.

Attach the clamp to the intake air surge tank assembly.

Attach the 2 wire harness clamps and connect the purge VSV connector to the purge VSV.

Connect the No. 4 water by-pass hose and No. 5 water by-pass hose to the throttle body with motor assembly, and slide the 2 clamps to secure the hoses.

Connect the throttle body with motor assembly connector.

Hide Display 4.CONNECT HEATER WATER HOSE ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION201902,201906,_51,_078603,_0381343,RM100000001FZPD_02_0130,201906,202107,_51,_078603,_0381343,RM100000001J10V_02_0130,202107,999999,_51,_078603,_0381343,RM100000001XZUR_02_0130,

Hide Display 22267A 5.INSTALL THROTTLE BODY BRACKET

Install the throttle body bracket to the timing chain or belt cover sub-assembly and intake air surge tank assembly with the 2 bolts.

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

w/ Secondary Air Injection System:

Install the air tube assembly to the throttle body bracket with the bolt.

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

Hide Display 17125 6.INSTALL NO. 1 SURGE TANK STAY

Install the No. 1 surge tank stay to the cylinder head LH and intake air surge tank assembly with the 2 bolts.

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

Attach the 2 wire harness clamps and install the wire harness with the bolt.

Torque:: 13 N*m (133 kgf*cm, 10 ft.*lbf)

Hide Display 17126 7.INSTALL NO. 2 SURGE TANK STAY

Install the No. 2 surge tank stay to the cylinder head LH and intake air surge tank assembly with the 2 bolts.

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

for Manual Transmission:

Install the flexible hose bracket to intake air surge tank assembly with the bolt.

Torque:: 20 N*m (204 kgf*cm, 15 ft.*lbf)

ii.

w/o Secondary Air Injection System:

Install the clutch pipe clamp to the No. 2 surge tank stay and clutch hose bracket with the bolt and nut.

Torque:: 13.5 N*m (138 kgf*cm, 10 ft.*lbf)

iii.

w/ Secondary Air Injection System:

Install the clutch pipe clamp to the No. 2 surge tank stay with the bolt.

Torque:: 13.5 N*m (138 kgf*cm, 10 ft.*lbf)

Hide Display 55701J 8.INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION201902,201906,_51,_078603,_0381343,RM100000001FZPD_02_0075,201906,202107,_51,_078603,_0381343,RM100000001J10V_02_0075,202107,999999,_51,_078603,_0381343,RM100000001XZUR_02_0075,

Hide Display 85110 9.INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

Click hereVehicle Exterior>WIPER / WASHER>FRONT WIPER MOTOR>INSTALLATION201902,999999,_59,_079320,_0385302,RM100000001GLKW,

Hide Display 17881 10.INSTALL NO. 1 AIR CLEANER HOSE

2.865,3.344 3.063,3.25 true 0.385,4.375 0.563,4.156 true 0.854,2.927 1.167,3.083 0.313,0.156 10 false *a 0.115,3.656 0.427,3.813 0.313,0.156 10 false *b 0.25,4.354 0.563,4.51 0.313,0.156 10 false *c 2.427,2.927 2.74,3.083 0.313,0.156 10 false *a 1.729,3.656 2.042,3.813 0.313,0.156 10 false *b 3.094,3.135 3.406,3.292 0.313,0.156 10 false *c

*a	Upper
*b	Front Side
*c	Stopper

Install the No. 1 air cleaner hose with the 2 hose clamps.

Torque:: 4.0 N*m (41 kgf*cm, 35 in.*lbf)

HINT:: Make sure the hose clamp is oriented as shown in the illustration.

Connect the No. 2 PCV hose to the No. 1 air cleaner hose, and slide the clamp to secure the hose.

Hide Display 11209 11.INSTALL V-BANK COVER SUB-ASSEMBLY (w/ Cover)

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION201902,201906,_51,_078603,_0381343,RM100000001FZPD_02_0003,201906,202107,_51,_078603,_0381343,RM100000001J10V_02_0003,202107,999999,_51,_078603,_0381343,RM100000001XZUR_02_0003,

Hide Display 12.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Click hereGeneral>MAINTENANCE>7GR-FKS BATTERY>INSTALLATION201902,999999,_V1,_078672,_0387105,RM100000001GV7O,

Hide Display 13. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>WORK PROCEDURE201902,201906,_V1,_081196,_0393338,RM100000001HX6R,201906,999999,_V1,_081196,_0393338,RM100000001JBY9,

HINT:: When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.; Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART201902,201906,_V1,_081196,_0393338,RM100000001HX6S,201906,999999,_V1,_081196,_0393338,RM100000001IWEY,

Hide Display 14.BLEED CLUTCH PIPE LINE (for Manual Transmission)

Click hereDrivetrain>CLUTCH>CLUTCH SYSTEM>BLEEDING201902,999999,_52,_078837,_0382375,RM100000001G4H4,

Hide Display 31301 15.INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>ADJUSTMENT201902,999999,_52,_078837,_0382376,RM100000001H07P_01_0001,

Hide Display 16.ADD ENGINE COOLANT

Click hereGeneral>MAINTENANCE>7GR-FKS COOLANT>REPLACEMENT201902,201906,_V1,_078672,_0386705,RM100000001GT6Z_01_0030,201906,202107,_V1,_078672,_0386705,RM100000001J08K_01_0030,202107,999999,_V1,_078672,_0386705,RM0000003TPC183_01_0030,

Hide Display 17.INSPECT FOR COOLANT LEAK

Click hereEngine / Hybrid System>7GR-FKS (COOLING)>COOLING SYSTEM>ON-VEHICLE INSPECTION201902,999999,_51,_079310,_0386557,RM100000001GS5S_01_0001,

Hide Display 18.INSPECT FOR FUEL LEAK

Click hereEngine / Hybrid System>7GR-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION201902,999999,_51,_079024,_0383258,RM100000001G9W0_01_0001,

Hide Display 51405A 19.INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION201902,201906,_51,_078603,_0381343,RM100000001FZPD_02_0096,201906,202107,_51,_078603,_0381343,RM100000001J10V_02_0096,202107,999999,_51,_078603,_0381343,RM100000001XZUR_02_0096,

Hide Display 52618 20.INSTALL LOWER FRONT BUMPER ABSORBER

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION201902,201906,_51,_078603,_0381343,RM100000001FZPD_02_0141,201906,202107,_51,_078603,_0381343,RM100000001J10V_02_0141,202107,999999,_51,_078603,_0381343,RM100000001XZUR_02_0141,

Hide Display 51406A 21.INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (w/ No. 2 Engine Under Cover Sub-assembly)

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION201902,201906,_51,_078603,_0381343,RM100000001FZPD_02_0097,201906,202107,_51,_078603,_0381343,RM100000001J10V_02_0097,202107,999999,_51,_078603,_0381343,RM100000001XZUR_02_0097,