Installation
INSTALLATION1. Clean all other parts and relevant mating faces.
2. If reinstalling the original manifold assembly (removed as an assembly for access to the intake manifold gasket/seals only) commence the installation instructions further on. Reinstall the Manifold Assembly to the Engine.
3. If installing a new manifold, assemble the components to the new inlet manifold.
4. Install the fuel pressure regulator to the manifold.
(1) Lubricate and install a new O-ring seal to the regulator.
(2) Install the pressure regulator to the manifold.
(3) Install the two bolts which secure the pressure regulator.
5. Install the fuel feed pipe to the manifold.
(1) Lubricate and install a new O-ring seal to the feed pipe.
(2) Install the feed pipe to the manifold.
(3) Install the two bolts which secure the feed pipe.
6. Install the fuel cross over elbow to the inlet manifold.
(1) Lubricate and install new O-ring seals to the cross over elbow.
(2) Install the cross over elbow to the manifold.
(3) Install the one bolt each side which secures the cross over elbow.
7. Install the sealing rings to the fuel injectors.
(1) Lubricate and install the sixteen (two to each injector) new sealing rings.
8. Install the fuel injectors to the intake manifold.
(1) Locate the injectors into the manifold.
(2) Position the injector clamping plates.
(3) Install the securing screws for each fuel injector and tighten to 4-6 Nm (35-52 inch lbs.).
9. Install the throttle induction elbow to the inlet manifold.
(1) Install a new induction elbow seal to the manifold.
(2) Install the elbow.
(3) Install the seven bolts which secure the throttle induction elbow.
10. Reinstall the Manifold Assembly to the Engine, as follows.
11. Install eight new seals to the inlet manifold ports.
12. Install the inlet manifold to the engine.
(1) Install the inlet manifold.
(2) Install the ten bolts which secure the inlet manifold.
13. Connect the fuel feed hose.
(1) Connect the fuel feed hose at the Quick Install connector.
^ Ensure that the hose is fully seated to the feed pipe.
14. Connect the fuel return hose.
(1) Connect the fuel return hose at the Quick Install connector.
^ Ensure that the hose is fully seated to the feed pipe.
15. Reconnect the electrical connector to each fuel injector.
16. Reinstall the induction elbow support; working from the left hand side.
(1) Install the upper bolt to the induction elbow support bracket.
(2) Tighten the lower two bolts at the induction elbow support bracket.
(3) Connect the engine breather T-piece to the induction elbow.
(4) Connect the vacuum pipe to the front of the induction elbow.
17. Install the induction elbow support; working from the right hand side.
(1) Install the upper bolt to the induction elbow support bracket.
(2) Reconnect the vacuum pipe to the center of the induction elbow.
18. Install the throttle body.
(1) Install a new gasket to the throttle body.
(2) Position the throttle body to the induction elbow.
19. Install the throttle body securing bolts and tighten to 18-24 Nm (13-18 ft. lbs.).
20. Reconnect the multi-plug, located on the bracket under the left side of the throttle body.
21. Connect the coolant hoses to the throttle body.
^ Remove the blanking plugs from the hoses.
^ Connect the coolant feed hose and secure with the clip.
^ Connect the coolant return hose and secure with the clip.
22. Reinstall the throttle cable & ensure that there is neither tension nor slack in the cable
^ Tighten the locknut without altering the setting or introducing twist into the cable outer
^ Check the kickdown setting using the PDU.
CAUTION: Under no circumstances may the quadrant be held clear of the throttle stop by cable tension
23. Reconnect the multi-plugs to the throttle body.
(1) Connect the throttle body motor multi-plug.
(2) Connect the two potentiometer multi-plugs, one each side of the throttle.
(3) Connect the vacuum pipe elbow to the throttle actuator.
24. Install the intake tube/air flow meter/air cleaner cover assembly.
(1) Install a new rubber seal; air intake tube to throttle body.
(2) Install the intake tube/air flow meter/air cleaner cover assembly.
25. Reconnect the air cleaner cover.
(1) Install the five clips which secure the air cleaner cover.
26. Connect the intake tube to the throttle body.
(1) Connect the intake tube to the throttle body.
(2) Install the two bolts which secure the intake tube to the throttle body.
27. Reconnect the air flow meter multi-plug.
28. Install a new strap to secures the vacuum pipe to the induction elbow.
29. Connect the breather pipe to the A-bank valve cover.
(1) Install a new O-ring seal to the breather pipe.
(2) Reconnect the breather pipe to the stub pipe.
30. Carefully reinstall the engine covers, taking care not to damage the plastic fixings or the rubber inserts.
31. Connect the battery ground cable. Reinstall the battery cover.
32. Perform the Battery Reconnection Procedure.
33. Check for leaks and that all pipes are securely connected. Remove the protection sheets, close the engine compartment, luggage compartment and doors.