Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Intake Manifold Assembly: Installation
- Install the cylinder head plate to the cylinder head.
- Install the fuel pipe protector stay.
Tightening torque:
19 N.m (1.9 kgf-m, 14.0 ft-lb)
- Set a new gasket and install the intake manifold assembly.CAUTION:
- Install the intake manifold assembly so that it is not damaged by adjacent parts.
- Be careful not to let the engine wiring harness be caught by the parts.
Tightening torque:
25 N.m (2.5 kgf-m, 18.4 ft-lb)
- Set a new gasket, and install the stud bolts using TORX® E5.
Tightening torque:
6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
- Temporarily attach the EGR pipe No. 2 and tighten it in order of 1→2→3.
Tightening torque:
9 N.m (0.9 kgf-m, 6.6 ft-lb)
- Install the PCV hose. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DOTC)>PCV HOSE>INSTALLATION .
- Install the harness stay.
Tightening torque:
6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
- Install the clip (A) and clip (B) to the harness stay.
- Connect the connector (A).
- Install the clip (B) and clip (C).
- Install the clip (C) and clip (D).
- Connect the fuel delivery pipe (B). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE B) .
- Connect the connector (A).
- Temporarily install the fuel pipe protector No. 2, and tighten the bolts.
Tightening torque:
19 N.m (1.9 kgf-m, 14.0 ft-lb)
- Temporarily attach the fuel pipe protector No. 1, and tighten the bolts securing the A/C compressor in numerical order as shown in figure.
Tightening torque:
25 N.m (2.5 kgf-m, 18.4 ft-lb)
- Install the V-belts. Ref. to MECHANICAL (H4DOTC)>V-BELT>INSTALLATION>V-BELT .
- Set the engine wiring harness and secure the engine wiring harness to the bracket with the claw.
- Install the engine wiring harness to the clip (A), and connect the connector (B).
- Connect the connector (C) and connector (D) in numerical order shown in figure.
- Secure the battery cable assembly with the claw (B) and clip (A).
- Install the V-belt cover bracket and install the connector (A).
Tightening torque:
6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
- Secure the battery cable assembly with the clip (A) and clip (B).
- Connect the connector (C), connector (D), connector (E), and the terminal (F).CAUTION: When connecting terminal (F), as residual anti-rust grease or dirt on the threads (bolts and nuts), terminals and seating surfaces may cause overtorque, clean and degrease them before connecting.
Tightening torque:
15.5 N.m (1.6 kgf-m, 11.4 ft-lb)
- After connecting terminal (F), apply a thin coat of anti-rust grease to the terminal section.CAUTION: This procedure is required to prevent rust and suppress sulfation.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.