Installation

1. INSTALL COLD START INJECTOR

(a) Install a new gasket and the injector with the two bolts.

Torque: 7.8 N-m (80 kgf.cm, 69 in.lbs)

Cold Start Injector Supply Line:

(b) Install the cold start injector tube with a new gasket and the union bolt.

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

Cold Start Injector Electrical Connector:

Air Intake Chamber:

2. INSTALL AIR INTAKE CHAMBER
(a) Place four new gaskets and the air intake chamber on the intake manifold.

EGR Pipe:

(b) Temporarily install a new gasket and the EGR pipe to air intake chamber with the two bolts.

Air Intake Chamber Components:

(c) Install the air intake chamber and following parts with the four bolts and eight nuts:
(1) Data link connector 1
(2) A/T throttle cable bracket
(3) VSV for fuel pressure control system
(4) VSV for EGR system

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

HINT: Use bolts 40 mm (1.57 in.) of length.

(d) Tighten the bolt holding the EGR pipe to the air intake chamber.

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

Cold Start Injector Supply Line:

(e) Connect the cold start injector tube to the RH delivery pipe with two new gaskets and union bolt.

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

Accelerator Bracket:

(f) Install the accelerator bracket with the bolt and stud bolt.

Air Intake Chamber Hoses:

3. CONNECT HOSES

Connect the following hoses:
(1) Water by-pass hose (from EGR valve) to water by-pass pipe
(2) Vacuum hose (from brake booster) to air intake chamber
(3) Vacuum hose (from VSV for heater water valve) to air intake chamber
(4) PCV hose to LH cylinder head cover

Air Intake Chamber Hoses:

(5) Water by-pass hose (from water inlet housing) to IAC valve
(6) Vacuum hose (from PS air control valve) to air intake chamber
(7) Vacuum sensing hose (from fuel pressure regulator) to vacuum pipe
(8) Two vacuum hoses (from VSV for EVAP system) to vacuum pipe
(9) Vacuum hose (from charcoal canister) to vacuum pipe

4. CONNECT CONNECTORS
Connect the following connectors:
^ Cold start injector connector
^ IAC valve connector
^ EGR valve connector
^ VSV connector for fuel pressure control system

PCV And By-pass Hoses:

5. INSTALL THROTTLE BODY
(a) Connect the following hoses:
(1) PCV hose to throttle body
(2) Water by-pass hose to throttle body

Throttle Body Installation:

(b) Install a new gasket and throttle body with the two bolts and two nuts.

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

HINT: Use bolts 40 mm (1.57 in.) in length.

(c) Install the water by-pass pipe (from rear water bypass joint) to the clamp on the engine wire cover.

Throttle Body Hoses:

(d) Connect the following hoses:
(1) Water by-pass hose to the IAC valve
(2) (USA Spec.)

Vacuum hose to throttle body

(3) (Exc. USA Spec.)

Three vacuum hoses to throttle body

Heater Hose:

(4) Heater water hose to heater water valve

TPS Connectors:

(e) Connect the following connectors:
(1) Throttle position sensor connector
(2) (W/ TRAC)
Sub-throttle position sensor connector
(3) (W/ TRAC)
Sub-throttle actuator connector

Lower High-tension Cord Cover:

5. INSTALL LOWER HIGH-TENSION CORD COVER
(a) Connect the end portions of the high-tension cord to the cord clamps
(b) Install the high-tension cord cover with the bolt.

(c) Install the clamps on the high-tension cords to the high-tension cord cover.
(d) Connect the high-tension cord to the RH ignition coil.

Right No. 3 Timing Belt Cover:

7. INSTALL RH NO.3 TIMING BELT COVER
(a) Install the three gasket to the timing belt cover.
(b) Fit portion A of the timing belt cover, matching it with the lower high-tension cord cover.
(c) Install the timing belt cover with the three bolts.

EVAP VSV:

8. INSTALL VSV FOR EVAP SYSTEM
Install the VSV with the two bolts.

Left No. 3 Timing Belt Cover:

9. INSTALL LH NO.3 TIMING BELT COVER
(a) Install the three gaskets to the timing belt cover.
(b) Install the cord grommet to the high-tension cord.
(c) Install the cord grommet to the timing belt cover.
(d) Fit portion A of the timing belt cover, matching it with the lower high-tension cord cover.
(e) Install the timing belt cover with the four bolts.

Right Engine Wire Cover:

10. INSTALL RH ENGINE WIRE COVER
(a) Fit portions A and B of the engine wire cover, matching them with the lower high-tension cord cover and No.3 timing belt cover.
(d) Install the engine wire cover with the bolt.

Left Engine Wire Cover:

11. INSTALL LH ENGINE WIRE COVER
(a) Connect portions A and B engine wire cover to the wire brackets.
(b) Set the VSV (for fuel pressure control system) wire in original position.
(c) Fit portions C and D of the engine wire cover, matching them with the lower high-tension cord cover and No.3 timing belt cover.
(d) Install the engine wire cover with the two bolts.

Upper High-tension Cord Cover:

12. INSTALL UPPER HIGH-TENSION CORD COVER
(a) Fit portion A of the upper high-tension cover, matching it with the top of the lower high-tension cord cover.
(b) Push the front side of the high-tension cord cover, and connect the front side claw groove of the upper high-tension cord cover to the claw of the lower high-tension cord cover.
(c) Install the upper high-tension cord cover with the two bolts.

Intake Air Connector:

13. INSTALL INTAKE AIR CONNECTOR
(a) Connect the end portions of the intake air connector to the throttle body and air cleaner hose.
(b) Tighten the two hose clamps.
(c) Install the bolt holding the intake air connector to the cylinder head cover.

Intake Air Connector Hoses:

(d) Connect the following hoses:
(1) Air hose to IAC valve
(2) Air hose (from PS air control valve) to intake air connector

Throttle Body Cables:

14. CONNECT CONTROL CABLES TO THROTTLE BODY
Connect the following cables:
(1) Accelerator cable
(2) A/T throttle control cable
(3) (W/ Cruise Control System)
Cruise control actuator cable

Throttle Body Cover:

15. INSTALL THROTTLE BODY COVER
Install the throttle body cover and hose clamp with the two bolts and cap nut.

16. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY

17. FILL WITH ENGINE COOLANT

18. CHECK FOR FUEL LEAKS