RM3660EC _51 Engine / Hybrid System _080790 8ZR-FXE INTAKE / EXHAUST _0392072 INTAKE MANIFOLD A

8ZR-FXE INTAKE / EXHAUST INTAKE MANIFOLD INSTALLATION

PROCEDURE

Hide Display 1.INSTALL STUD BOLT (w/ Stud Bolt)

HINT:: If a stud bolt is deformed or the threads are damaged, replace it.

Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

Torque:: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

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

Install a new No. 1 intake manifold to head gasket to the intake manifold.

Hide Display 17111 3.INSTALL INTAKE MANIFOLD

Temporarily install the intake manifold to the cylinder head sub-assembly with the 3 bolts and 2 nuts.

0.083,0.052 0.24,0.219 0.156,0.167 10 true 5 0.604,0.021 0.76,0.188 0.156,0.167 10 true 2 1.365,0.031 1.521,0.198 0.156,0.167 10 true 1 2.469,0.042 2.625,0.208 0.156,0.167 10 true 3 3.229,0.146 3.385,0.313 0.156,0.167 10 true 4

	Bolt
	Nut

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

Torque:: 28 N*m (286 kgf*cm, 21 ft.*lbf)

Hide Display 4.CONNECT WATER BY-PASS HOSE

0.427,0.365 0.583,0.365 0.583,0.365 0.688,0.667 true 1.969,0.208 1.833,0.208 1.833,0.208 1.698,0.51 true 1.979,0.115 2.198,0.302 0.219,0.188 10 true *1 0.24,0.281 0.448,0.469 0.208,0.188 10 true *2

*1	Water By-Pass Hose
*2	No. 2 Water By-pass Hose

Engage the 2 hose clamps to connect the No. 2 water by-pass hose to the intake manifold.

Engage the 2 hose clamps to connect the water by-pass hose to the intake manifold.

Hide Display 23827A 5.CONNECT NO. 2 FUEL VAPOR FEED HOSE

Engage the 2 hose clamps.

Connect the No. 2 fuel vapor feed hose to the intake manifold.

Hide Display 16296 6.CONNECT NO. 8 WATER BY-PASS HOSE

Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.

Engage the 2 hose clamps.

Hide Display 7.CONNECT ENGINE COVER BRACKET

Connect the engine cover bracket to the intake manifold with the bolt.

Torque:: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Hide Display 82121 8.CONNECT ENGINE WIRE

Engage the clamp and connect the engine wire with the bolt.

Torque:: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Connect the 4 fuel injector assembly connectors and purge valve (purge VSV) connector.

Connect the wire harness bracket with the bolt.

Torque:: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Connect the engine water pump assembly connector.

Engage the 2 clamps.

Hide Display 12261 9.CONNECT VENTILATION HOSE

Connect the ventilation hose to the intake manifold and slide the clip to secure it.

Hide Display 89421 10.INSTALL E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)

Install the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) to the intake manifold with the bolt.

Torque:: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

Connect the vacuum hose to the intake manifold.

Connect the E.F.I. vacuum sensor assembly (manifold absolute pressure sensor) connector.

Hide Display 25610 11.INSTALL EGR PIPE ASSEMBLY

2.302,0.969 2.719,0.74 2.719,0.74 2.354,1.281 true 0.74,0.5 0.5,0.479 0.5,0.479 0.656,0.938 true 0.323,0.292 0.51,0.49 0.188,0.198 10 true *a 2.729,0.615 2.917,0.813 0.188,0.198 10 true *a

Claw

Install a new EGR pipe gasket to the EGR valve assembly.

NOTICE:: Make sure that the claws of the EGR pipe gasket are toward the EGR valve assembly side.

1.146,1.094 1.531,1.094 true 1.927,1.813 2.083,1.813 2.083,1.813 2.281,1.25 true 0.948,0.979 1.146,1.198 0.198,0.219 10 true *a 1.719,1.729 1.938,1.938 0.219,0.208 10 true *b

*a	Groove
*b	Protrusion

Install a new inlet EGR gasket to the intake manifold.

HINT:: Align the protrusion of the inlet EGR gasket with the groove of the intake manifold.

Install the EGR pipe assembly to the intake manifold and EGR valve assembly with the 4 bolts.

Torque:: 8.5 N*m (87 kgf*cm, 75 in.*lbf)

Hide Display 17751 12.INSTALL INLET NO. 1 AIR CLEANER

Install the inlet No. 1 air cleaner to the intake manifold with the 2 bolts.

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

Hide Display 17771A 13.INSTALL AIR CLEANER BRACKET

Engage the 2 wire harness clamps and the hose clamp, and attach the air cleaner bracket to the cylinder block sub-assy, the air conditioner conditioning wire, and the No. 1 radiator hose with 2 bolts.

Torque:: 12 N*m (122 kgf*cm, 9 ft.*lbf)

Hide Display 17701 14.INSTALL AIR CLEANER CASE SUB-ASSEMBLY

Install the air cleaner case sub-assembly to the air cleaner bracket with the 2 bolts.

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

Hide Display 17801 15.INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

Hide Display 17752 16.INSTALL INLET NO. 2 AIR CLEANER

3.104,1.229 3.104,0.406 true 2.521,1.646 2.521,0.823 true 2.427,1.677 2.677,1.833 0.25,0.156 10 true *a 3.01,1.229 3.219,1.417 0.208,0.188 10 true *b

*a	Groove
*b	Protrusion

Install the air cleaner inlet No. 2 to the air cleaner inlet No. 1 and the radiator support sub-assembly UPR with bolt and clips.

HINT:: Align the protrusion of the inlet No. 1 air cleaner with the groove of the inlet No. 2 air cleaner.

Tighten the bolt.

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

Install the clip.

Hide Display 53289A 17.INSTALL RADIATOR SUPPORT OPENING COVER

for TFTM Made:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for TFTM Made)>INSTALLATION202304,202307,_59,_080736,_0392548,RM100000002AMO6_01_0050,202307,999999,_59,_080736,_0392548,RM100000002CH8W_01_0050,

for GTMC Made:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for GTMC Made)>INSTALLATION202304,202307,_59,_080736,_0392547,RM100000002AXCP_01_0052,202307,999999,_59,_080736,_0392547,RM100000002CHFB_01_0052,

Hide Display 22210 18.INSTALL THROTTLE BODY ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE CONTROL)>THROTTLE BODY>INSTALLATION202304,999999,_51,_080778,_0392133,RM10000000295TX,