Installation

Removing The Six Bolts For Intake Manifold:

1. Install new gasket and intake manifold with the six bolts and two nuts. Uniformly tighten the nuts and bolts to 19 Nm (14 ft lb) in several passes.
2. Connect the two wire clamps to the wire brackets on the intake manifold.

Removal Of Intake Manifold:

3. Install the vacuum hose bracket and engine wire harness with the bolt.
4. Install the No. 1 air intake chamber and manifold stays wire bracket with the four bolts, then torque the 14 mm head bolts to 42 Nm (31 ft lb); torque the 12 mm head bolts to 22 Nm (16 ft lb).

Disconnecting Engine Ground Wire From Intake Manifold:

5. Connect the knock sensor and Exhaust Gas Recirculation (EGR) Vacuum Switching Valve (VSV) connectors.
6. Install engine wire ground strap to the intake manifold.

Removal Of Three Bolts, Wire Clamp, And Air Tube:

7. Install the air tube and wire clamp with the three bolts.

Removal Of Air Tube:

8. Connect the Air hose from the A/C air switching valve, if equipped with A/C; connect the two air hose from the PS pump.

Disconnecting Vacuum Hoses:

9. Connect the vacuum sensor hose to the intake chamber, the brake booster vacuum hose from air intake chamber, and vacuum sensing hose.
10. If equipped with A/C, connect the A/C magnet switch VSV connector.

Removal Of EGR Components:

11. Install the EGR valve with a new gasket, then torque the bolts to 13 Nm (9 ft lb). Connect the union nut, then torque the union nut to 59 Nm (43 ft lb).
12. Install the EGR vacuum modulator to the clamp.

Connecting Vacuum Hose Clamps:

13. Connect the vacuum hose clamp, then connect the following hoses:
a. Vacuum hose to the charcoal canister.
b. Vacuum hose from EGR valve to E port of EGR VSV.
c. Vacuum hose from Q port of EGR vacuum modulator to G port of EGR VSV.
d. On California models only, connect the EGR gas temperature connector.

Installing Throttle Body:

14. Install the throttle body.
a. Connect the water by-pass hose to water outlet. (Number 1 in image)
b. Connect the water by-pass hose to water by-pass pipe. (Number 2 in image)
c. Connect the air hose to air tube. (Number 3 in image)

Installing Throttle Body Gasket:

15. Place a new gasket on the throttle body, with the protrusion facing downward.

Installing Throttle Body Bolts:

16. Install the throttle body with the four bolts, and torque each bolt to 19 Nm (14 ft lb). Each bolt is indicated in the illustration. Bolt length is:
A Bolt 45 mm (1.77 in)
B Bolt 55 mm (2.17 in)

Hose Removal From Throttle Body:

17. Connect the following hoses to the throttle body:
a. PCV hose (Number 1 in image)
b. Two vacuum hoses to the EGR vacuum modulator (Number 2 in image)
c. Vacuum hose to the EGR VSV. (Number 3 in image)
18. Connect the ISC valve connector, then connect the throttle position sensor connector.

Removal of Air Cleaner, Resonator, And Air Cleaner Hose:

19. Install air cleaner cap, resonator, and air cleaner hose.
a. Connect the air cleaner hose to the throttle body.
b. Install the air cleaner cap together with the resonator and air cleaner hose.
c. Connect the air intake temperature sensor connector.
d. Connect the cruise control actuator cable to the clamp on the resonator and air cleaner cap.
20. If equipped with A/T, connect the throttle cable and adjust.
21. Connect the accelerator cable and adjust.
22. Add necessary coolant to top off radiator.
23. Connect cable to negative terminal of battery.
24. Start engine and check for leaks.
25. Perform road test; check for abnormal noise, shock, slippage, shift points and smooth operation.
26. Recheck engine coolant level.