Installation
PROCEDURE1. Install injectors and delivery pipe.
O-ring Installation:
- Install a new grommet to the injector.
- Apply a light coat of gasoline to a new 0-ring, and install it to the injector.
- While turning the injector clockwise and counterclockwise, push it to the delivery pipe. Install the 8 injectors.
- Position the injector connector outward.
- Place 8 new insulators and the 4 spacers in position on the intake manifold.
- Place the 8 injectors and 2 delivery pipes assembly in position on the intake manifold.
- Temporarily install the connector bracket and 4 nuts.
- Check that the injectors rotate smoothly. If injectors do not rotate smoothly, the probable cause is incorrect installation of 0-rings. Replace the 0-rings.
- Position the injector connector upward.
- Tighten the 4 nuts holding the delivery pipes to the intake manifold.
Torque: 18 Nm (13 ft lb)
2. Temporarily install the return pipe with 2 new gaskets, union bolt and bolt.
- Tighten the union bolt holding the return pipe to the pressure regulator.
Torque: 35 Nm (26 ft lb)
- Tighten the bolt holding the return pipe to the cylinder head.
3. Tighten lock nut on fuel pressure regulator.
Torque: 29 Nm (22 ft lb)
Engine Wire Connectors:
4. Install engine wire to delivery pipes, rear water bypass joint and right hand cylinder head.
- Connect the 8 injector connectors.
- Connect the 2 engine wire connectors to the connector bracket on the left hand delivery pipe.
- Install the engine wire to the right hand cylinder head with the 2 bolts.
- Install the engine wire to the rear water bypass joint with the 2 bolts.
- Install the engine wire to the delivery pipes with the 4 bolts.
5. Install engine wire to intake manifold with the 2 bolts.
6. Connect fuel return hose to fuel return pipe. Connect fuel inlet hose to left hand delivery pipe.
- Using SST, connect the inlet hose with 2 new gaskets and pulsation damper. (SST 09612-24014)
Torque: 39 Nm (29 ft lb)
33 Nm (24 ft lb) for SST
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.)
7. Install air intake chamber assembly.
- Place 4 new air intake chamber gaskets and the air intake chamber assembly on the intake manifold.
- Temporarily install a new gasket and the exhaust gas recirculation pipe to air intake chamber with the 2 bolts.
- Install the connector bracket to the data link connector 1.
- Install the air intake chamber and following parts with the 4 bolts and 8 nuts:
- Data link connector 1.
- Transmission throttle cable bracket.
- Vacuum switching valve for fuel pressure control.
- Vacuum switching valve for evaporative emissions.
- Vacuum switching valve for air injection system (california models).
Torque: 18 Nm (13 ft lb)
HINT: Use bolts 40 mm (1.57 in.) of length.
- Tighten the bolts holding the exhaust gas recirculation pipe to the air intake chamber.
Torque: 18 Nm (13 ft lb)
8. Connect the following hoses:
- Water bypass hose from water inlet housing from idle air control valve.
- Vacuum hose from power steering air control valve from air intake chamber.
- Vacuum sensing hose from fuel pressure regulator from vacuum pipe.
- Water bypass hose from exhaust gas recirculation valve.
- Vacuum hose (from brake booster) from air intake chamber.
- Vacuum hose (from vacuum switching valve for air injection system) from air injection pump outlet pipe.
- Positive crankcase ventilation hose from left hand cylinder head cover.
9. Connect the following connectors:
- Idle air control valve connector
- Exhaust gas recirculation valve connector
- Vacuum switching valve connector for fuel pressure control
- Vacuum switching valve connector for evaporative emissions system.
- Exhaust gas recirculation temperature sensor connector.
- Vacuum switching valve connector for air injection system (california models).
10. Install throttle body.
- Connect the following hoses to the throttle body:
- positive crankcase ventilation hose (1)
- Water bypass hose (2)
- Install a new gasket and throttle body with the 2 bolts and 2 nuts.
Torque: 18 Nm (13 ft lb)
HINT: Use bolts 40 mm (1.57 in.) in length.
- Install the water bypass pipe from rear water bypass joint to the clamp on the engine wire cover.
- Connect the following hoses:
- Water bypass hose to idle air control valve (1)
- California: Vacuum hose to throttle body (2)
- Connect the following connectors:
- Throttle position sensor connector (1)
- w/TRAC: Sub-throttle position sensor connector (2)
- w/ TRAC: Sub-throttle actuator connector (3)
- Connect the radiator hose to front water bypass joint.
- Connect the radiator hose to water inlet housing.
11. Install lower high-tension cord cover.
- Connect the end portions of the high-tension cord to the cord clamps
- Install the high-tension cord cover with the bolt.
- Install the clamps on the high-tension cords to the high-tension cord cover.
- Connect the high-tension cord to the righthand ignition coil.
12. Install righthand No. 3 timing belt cover.
- Install the 3 gaskets to the timing belt cover.
- Fit the portion A of the timing belt cover. matching it with the lower high-tension cord cover.
- Install the timing belt cover with the 4 bolts.
- Connect the 2 air control hoses on the power steering pump to the hose clamp on the timing cover.
13. Install lefthand No.3 timing belt cover.
- Install the 3 gaskets to the timing belt cover.
- Install the cord grommet to the high-tension cord (from the lefthand ignition coil).
- Install the cord grommet to the timing belt cover.
- Fit the portion A of the timing belt cover, matching it with the lower high-tension cord cover.
- Install the timing belt cover with the 4 bolts.
- Connect the evaporative emissions hose to the hose clamp on the timing belt cover.
14. Install righthand engine wire cover.
- Fit the portions A and B of the engine wire cover, matching them with the lower high-tension cord cover and No. 3 timing belt cover.
- Install the engine wire cover with the bolt.
15. Install lefthand engine wire cover.
- Connect the portions A and B of the engine wire cover to the wire brackets.
- Set the evaporative emissions hose and vacuum switching valve (for the fuel pressure) wire in original position.
- Fit the portions C and D of the engine wire cover, matching them with the lower high-tension cord cover and No. 3 timing belt cover.
- Install the engine wire cover with the 2 bolts.
16. Install intake air connector.
- Connect the end portions of the intake air connector to the throttle body and air cleaner hose.
- Tighten the 2 hose clamps.
- Connect the following hoses:
- Air hose to idle air control valve (1)
- Air hose (from air control valve on power steering pump) to intake air connector (2)
- Install the air cleaner assembly.
- install the engine compartment relay box cover.
- Install the battery and clamp cover.
- Install the No. 2 air cleaner hose with the bolt.
17. Connect negative terminal cable to battery.
18. Fill engine with coolant.
19. Check for leaks.