Installation

O-ring Installation:

1. INSTALL INJECTORS TO DELIVERY PIPES

(a) Install two new grommets to the injector.

(b) Apply a light coat of gasoline to two new o-rings and install them to the injector.

Spacers And Insulators:

2. INSTALL RH DELIVERY PIPE AND INJECTORS

(a) Place the two spacers in position on the intake manifold.

Clean the injector holes before installing the injectors into the intake manifold.

Injector Connector Orientation:

(b) Place the three injectors together with the RH delivery pipe and No.1 fuel pipe in position on the intake manifold.

(c) Check that the injectors rotate smoothly.

HINT: If the injectors do not rotate smoothly, the probable cause is incorrect installation of o-rings. Replace the o-rings.

(d) Position the injector connector upward.

RH Delivery Pipe:

(e) Install and tighten the three bolts.

Torque: 13 N-m (130 kgf.cm, 9 ft.lbs)

Air Pipe:

3. INSTALL AIR PIPE WITH HOSES

(a) install the air pipe with the two bolts.

Torque: 8.3 N-m (85 kgf.cm, 74 in.lbs)

(b) Connect the two air hoses.

Left Side Fuel Rail:

4. INSTALL LH DELIVERY PIPE AND INJECTORS

(a) Place the two spacers in position on the intake manifold.

Clean the injector holes before installing the injectors into the intake manifold.

Injector Connector Orientation:

(b) Place the three injectors together with the LH delivery pipe in position on the intake manifold.

(c) Check that the injectors rotate smoothly.

HINT: If the injectors do not rotate smoothly, the probable cause is incorrect installation of rings. Replace the rings.

(d) Position the injector connector upward.

Fuel Rail:

(e) Install and tighten the two bolts.

Torque: 13 N-m (130 kgf.cm, 9 ft.lbs)

(f) Connect the fuel hose to the No.1 fuel pipe.

No. 2 Fuel Pipe:

5. INSTALL NO.2 FUEL PIPE

(a) Install the No.2 fuel pipe with four new gaskets and the two union bolts.

Torque: 34 N-m (350 kgf.cm, 25 ft.lbs)

(b) Connect the IACV vacuum hose.

6. CONNECT INJECTOR CONNECTORS

Fuel Lines:

7. CONNECT FUEL INLET AND RETURN HOSES

(a) Connect the inlet hose to the fuel filter with two new gaskets and union bolt.

Torque: 29 N-m (300 kgf.cm, 22 ft.lbs)

(b) Connect the return hose to the No.1 fuel pipe.

Air Intake Chamber Installation:

8. INSTALL AIR INTAKE CHAMBER

(a) Using 8 mm hexagon wrench, install a new gasket and the air intake number with the two bolts and nuts. Torque: 43 N-m (440 kgf.cm, 32 ft.lbs)

Air Intake Chamber Removal:

(b) Connect the throttle position sensor connector.

(c) Connect the IAC valve connector.

(d) Connect the IAC valve air hose.

(e) Connect PS air hose.

Intake Manifold Hoses:

(f) (Calif. only)

Connect the EGR gas temp. sensor connector.

(g) Connect the following hoses:

(1) Water by-pass hose to throttle body

(2) Water by-pass hose to EGR cooler

(3) Vacuum hose (from EGR valve) to TVV (for EGR)

(4) Vacuum hose (from EGR vacuum modulator) to TVV (for EGR)

(5) Vacuum hose (from throttle body) to TVV (for EVAP)

9. CONNECT HYDRAULIC MOTOR PRESSURE PIPE

Connect the hydraulic pressure pipe to the air intake chamber with the bolt.

10. INSTALL EGR PIPE

Install a new gasket, sleeve ball and the EGR pipe with

the two bolts and union nut.

Bolt

Torque: 18 N-m (185 kgf.cm, 13 ft.lbs)

Union nut

Torque: 78 N-m (800 kgf.cm, 58 ft.lbs)

Air Chamber Stay:

11. INSTALL NO.1 ENGINE HANGER AND AIR INTAKE CHAMBER STAY

(a) Install the air intake chamber stay with the two bolts.

Torque: 39 N-m (400 kgf.cm, 29 ft.lbs)

(b) Install the No.1 engine hanger with the two bolts.

Torque: 39 N-m (400 kgf.cm, 29 ft.lbs)

Cold Start Injector:

12. CONNECT COLD START INJECTOR PIPE (NO. 2 FUEL PIPE)

Connect the injector pipe with two new gaskets and union bolt.

Torque: 15 N-m (150 kgf.cm. 11 ft.lbs)

13. CONNECT COLD START INJECTOR CONNECTOR

Ground Straps:

14. CONNECT GROUND STRAPS

Connect the two ground straps with the nut. Torque: 13 N-m (130 kgf.cm. 9 ft.lbs)

15. CONNECT HOSES

(a) Brake booster vacuum hose

(b) PS air hose

(c) PCV hose

(d) IACV vacuum hose

Emission Control Valve Set Removal:

16. INSTALL EMISSION CONTROL VALVE SET

(a) Install the emission control valve set with the two bolts.

(b) Connect the two VSV connectors.

(c) Connect the two vacuum hoses of the IACV VSV.

(d) Connect the two vacuum hoses of the fuel pressure control VSV.

(e) Connect the EGR gas temp. sensor connector clamp to the emission control valve set.

V-Bank Cover:

17. INSTALL V-BANK COVER

Using a 5 mm hexagon wrench. install the V-bank cover with the two nuts.

Intake Air Hose:

18. INSTALL AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE

(a) Connect the air cleaner hose, and install the air cleaner cap and volume air flow meter with the four clips.

(b) Tighten the air cleaner hose clamp bolt.

(c) Connect the air hoses.

(d) Connect the coil cord clamp.

(e) Connect the volume air flow meter connector.

19. (A/T)

CONNECT THROTTLE CABLE, AND ADJUST IT

20. CONNECT ACCELERATOR CABLE, AND ADJUST IT

21. FILL WITH ENGINE COOLANT

22. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY