Throttle Body & Intake Manifold: Installation

1. Install new intake manifold gasket (1) to cylinder head. See Fig 7 .
2. Install intake manifold (2). Tighten bolts and nuts to specified torque.
3. Connect coolant pipe (1) to intake manifold. See Fig 6 .
4. Install intake manifold front stiffener and rear stiffener. See Fig 5 . Tighten bolts to specified torque. See TORQUE SPECIFICATIONS  .
5. Install throttle body (1) to intake manifold (3) with new gasket (2). See Fig 4 . Tighten bolts and nuts to specified torque. See TORQUE SPECIFICATIONS  .
6. Connect the following hoses:
   • Brake booster hose to intake manifold
   • PCV hose to PCV valve
   • Fuel pressure regulator vacuum hose to intake manifold
   • Coolant hoses to throttle body and cylinder head
   • Breather hose to throttle body
   • Vacuum hose to EVAP canister purge valve
   See Fig 3 .
7. Connect the following electric lead wires:
   • IAC valve
   • TP sensor
   • MAF sensor
   • EGR valve
   • EVAP canister purge valve
   • MAP sensor
   • Ground terminal from throttle body
   See Fig 2 .
8. Connect accelerator cable (1) to throttle body. Install its bracket (2) to the intake manifold. See Figure . Adjust accelerator cable play. See ACCELERATOR CABLE  under ADJUSTMENTS.
9. Install air cleaner outlet hose.
10. Install engine cover. See ENGINE COVER  .
11. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
12. Refill cooling system.
13. Connect negative cable at battery.
14. Finally, start engine and check for engine coolant leaks.

1. Reverse removal procedure noting the following:
   • Use new intake manifold gasket (2). See Fig 4 .
   • Install fuel delivery pipe with fuel injectors to cylinder head referring to "Fuel Injector Removal and Installation.
   • Adjust accelerator cable (1) play and A/T throttle cable (2) play (for vehicle with A/T). See ACCELERATOR CABLE  and THROTTLE CABLE  .
   • Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
   • Refill cooling system.
   • Upon completion of installation, turn ignition switch ON but engine OFF and check for fuel leaks.
   • Finally, start engine and check for engine coolant leaks.

1. Install new intake manifold gaskets (1) to cylinder heads. See Fig 12 .
2. Install intake manifold (1) and tighten bolts (2) and nuts (3). See Fig 11 .
3. Install throttle body (2) to intake collector (1) with new throttle body gasket. See Fig 13 .
4. Install IAC valve (1), EGR valve (2), EVAP canister purge valve (3), manifold absolute pressure (MAP) sensor, clamps and each hoses to intake collector and throttle body if removed. See Fig 14 .
   NOTE: Use new gasket, when installing IAC valve and EGR valve.
5. Install throttle body and intake collector assembly to intake manifold with new intake collector gaskets.
6. Connect heater hose (1), EVAP canister hose (4), tank pressure control solenoid valve hose, fuel feed hose (2) and fuel return hose (3). See Fig 8 .
7. Install EGR pipe (3) with new gaskets. See Fig 7 .
8. Connect EVAP canister purge valve hose (4) and heater hose (5). See Fig 7 .
9. Connect PCV hose (6), breather hose (8) and water hose (7). See Fig 7 .
10. Connect couplers of manifold absolute pressure (MAP) sensor, EVAP canister purge valve (1) and EGR valve (2). Fix wire harness with clamps. See Fig 7 .
11. Install clamp bracket (5) to intake collector. See Fig 6 .
12. Connect earth terminal (4) to intake collector. See Fig 6 .
13. Connect TP sensor coupler (1), MAF sensor coupler (2) and IAC valve coupler (3). See Fig 6 .
14. Connect brake booster hose (2) to intake manifold. See Fig 5 .
15. Connect injector wire (1) coupler. See Fig 5 .
16. Connect water hoses (3) to throttle body. See Fig 4 .
17. Connect accelerator cable (1) and A/T throttle cable (for A/T model) (2) to throttle body and adjust these cables, referring to ACCELERATOR CABLE  and THROTTLE CABLE  . See Fig 4 .
18. Install surge tank pipe (2) to intake manifold with new gaskets and intake air pipe (1) to throttle body. See Fig 3 .
19. Install surge tank cover (1). See Fig 2 .
20. Install air cleaner upper case referring to AIR CLEANER ELEMENT  .
21. Connect coupler to intake air temperature sensor.
22. Install strut tower bar (1) and tighten strut tower bar mounting bolts (2) to.specification. See Fig 15 & TORQUE SPECIFICATIONS  .
23. Install fuse/relay box.
24. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
25. Refill cooling system.
26. Connect negative cable at battery.
27. Upon completion of installation, verify that there is no fuel leakage at each connection.