RM3660EC _51 Engine / Hybrid System _080791 NR Series INTAKE / EXHAUST _0392517 INTAKE MANIFOLD A

NR Series INTAKE / EXHAUST  INTAKE MANIFOLD  INSTALLATION  


PROCEDURE

Hide 1.INSTALL STUD BOLT

a.

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

a.

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


Hide 17111 3.INSTALL INTAKE MANIFOLD

a.
A355595C02
2.094,1.052 1.792,0.604 1.792,0.604 1.604,0.604 true 1.396,0.552 1.646,0.75 0.25,0.198 10 true *a
*a O-ring


Apply a light coat of engine oil to the O-ring of the PCV valve (ventilation valve sub-assembly).


b.

Temporarily install the intake manifold to the cylinder head sub-assembly with the 5 bolts.


c.
A353280E02
1.865,1.24 2.052,1.438 0.188,0.198 10 true 1 1.01,1.125 1.198,1.323 0.188,0.198 10 true 2 2.5,0.563 2.688,0.76 0.188,0.198 10 true 3 3.031,0.781 3.219,0.979 0.188,0.198 10 true 5 0.281,0.979 0.417,1.156 0.135,0.177 10 true 4

Tighten the 5 bolts in the order shown in the illustration.

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


Hide 23829 4.INSTALL NO. 3 FUEL VAPOR FEED HOSE

a.

Install the No. 3 fuel vapor feed hose to the intake manifold and slide the clip to secure it.


Hide 82121 5.CONNECT ENGINE WIRE

a.

Engage the wire harness clamp.


b.

Engage the engine wire with the bolt.

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


c.

Connect the No. 2 water by-pass hose to the intake manifold.


d.

Install the wire harness clamp bracket to the intake manifold with the bolt.

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


e.

Engage the wire harness clamp to the wire harness clamp bracket.


f.

Install the wire harness clamp bracket to the intake manifold with the bolt.

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


g.

Engage the wire harness clamp.


Hide 22271 6.INSTALL THROTTLE BODY GASKET

a.
A445047C01
1.74,0.719 2.104,0.281 2.104,0.281 2.313,0.281 true 2.333,0.219 2.531,0.417 0.198,0.198 10 true *a
*a Protrusion


Install a new throttle body gasket to the intake manifold with the protrusion of the throttle body gasket oriented as shown in the illustration.


Hide 22030 7.INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

a.

Install the throttle body with motor assembly to the intake manifold.

NOTICE:
·

Do not drop the throttle body with motor assembly.

·

If the throttle body with motor assembly has been struck or dropped, replace it.



HINT:

Perform Inspection After Repair after replacing the throttle body with motor assembly.

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION



b.

Connect the No. 1 water by-pass hose and No. 2 water by-pass hose to the throttle body with motor assembly and slide the 2 clips to secure them.


c.

Connect the throttle body with motor assembly connector.