Intake Duct Installation - Pioneer 1200 Maintenance Service Manual

14
FUEL SYSTEM

INTAKE DUCT INSTALLATION

1. Pioneer 1200:
The intake duct assembly is installed from the front of the vehicle, in reverse order of removal. See fol-
lowing NOTE.
NOTE: This procedure is best accomplished using two people.
1.1. Slide the intake duct between the round crossmember and the floorboard, moving it to the rear
along the underside of the floorboard.
NOTE: It is best to have a second person guide the air box end of the duct into position as it is pushed from
the front of the vehicle. Insert the end of the intake duct through the slot in the front of the air box
mounting plate.
1.2. Secure the front of the duct to the underside of the floorboard with pop rivet (24) and flat washers
(25) (Figure 14-10, Page 14-17).
1.3. Place a piece of double-sided adhesive tape on the intake shield and remove the adhesive backing.
See following NOTE.
NOTE: If necessary, reform any minor deformation of the shield and clean the old double-sided adhesive
tape cleanly from both the shield and vehicle frame before installation of the shield.
1.4. Install the shield to the frame with the adhesive strip and pop rivet (30).
1.5. Install air box. See Air Box Installation on page 14-11.
1.6. Assemble front end components. See following NOTE.
NOTE: This procedure is best accomplished using two people.
1.6.1. Attach each of the front A-arms to the to the shock tower at the top shock mount and bot-
1.6.2. Position the top edge of the strap plate (27) onto the frame and install the two bolts (26),
1.6.3. Tighten bolts (28) at the shock tower and strip plate (27) to 20 ft-lb (27 N·m).
1.6.4. Tighten bolts (26) at the top of the strip plate (27) and frame to 20 ft-lb (27 N·m).
1.6.5. Install steering joint. See following NOTE.
NOTE: Make sure steering wheel and front wheels are properly aligned before installing steering joint.
The steering column shaft has a machined flat area provided for passage of the bolt when assem-
bled to the steering joint.
1.6.6. Slip the splined steering joint over the splined steering column shaft, aligning with the mark
1.6.7. Attach the rack and pinion assembly to the shock tower plate using the four bolts (2) and
1.6.8. Tighten the bolt (1) of the steering joint flange to 15 ft-lb (20.3 N·m).
1.7. Install the front wheels and tighten the wheel lug nuts finger-tight.
1.8. Lower the vehicle and tighten the wheel lug nuts, using a crisscross pattern, to 55 ft-lb (75 N·m).
1.9. Install front body. See Front Body Installation, Section 4, Page 4-4.
Page 14-14 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
tom hole locations of the strip plate (27) using bolts (28) and lock nuts. Do not tighten
(Figure 14-10, Page 14-17).
flat washers and lock nuts. Do not tighten.
made during disassembly. Attach the bolt (1) through the steering joint flange and loosely
attach the nut (Figure 14-9, Page 14-13).
lock nuts (Figure 14-9, Page 14-13). Tighten to 20 ft-lb (27 N·m).
Choke and Air Intake System