Installation
PROCEDURE
1. Install a new gasket and the cold start injector to the intake manifold with the 2 bolts.
Torque: 7.8 Nm (69 in lb)
- install the cold start injector tube with 2 new gaskets and union bolt.
Torque: 15 Nm (11 ft lb)
- Connect the lead wire connector to the cold start injector.
2. Install air intake chamber assembly.
- Place 4 new air intake chamber gaskets on the intake manifold.
- California: Connect the exhaust gas recirculation gas temperature sensor connector.
- Place 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.
- Except California: 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 (1)
- transmission throttle cable bracket (2)
- vacuum switching valve for fuel pressure control (3)
- vacuum switching valve for evaporative emissions (4)
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)
- Tighten the bolt holding the exhaust gas recirculation pipe to the right hand cylinder head.
Torque: 18 Nm (13 ft lb)
- Connect the cold start injector tube to the right hand delivery pipe with the 2 new gaskets and union bolt.
Torque: 15 Nm (11 ft lb)
- Install the accelerator bracket with the bolt and stud bolt.
3. Connect the following hoses:
- Water bypass hose (from exhaust gas recirculation valve) to water bypass pipe (1)
- Vacuum hose (from brake booster) to air intake chamber (2)
- Vacuum hose (from vacuum switching valve for heater water valve) to air intake chamber (3)
- Positive crankcase ventilation hose to left hand cylinder head cover (4)
- Water bypass hose from water inlet housing to idle air control valve (5)
- Vacuum hose from PS air control valve to air intake chamber (6)
- Vacuum sensing hose from fuel pressure regulator to vacuum pipe (7)
- 2 vacuum hoses from vacuum switching valve for evaporative emissions to vacuum pipe (8)
- Vacuum hose from charcoal canister to vacuum pipe (9)
4. Connect the following connectors:
- Cold start injector connector.
- Idle air control valve connector.
- California: exhaust gas recirculation valve connector.
- Except California: vacuum switching valve connector for exhaust gas recirculation.
- Vacuum switching valve connector for fuel pressure control.
5. 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 AC valve (1)
- California: Vacuum hose to throttle body (2)
- Except California: 3 vacuum hoses to throttle body (3)
- Heater water hose to heater water valve (4)
- Connect the following connectors:
- Throttle position sensor connector (1)
- w/TRAC: Sub-throttle position sensor connector (2)
- w/ TRAC: Sub-throttle actuator connector (3)
6. 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 right hand ignition coil.
7. Install right hand 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 3 bolts.
8. Install vacuum switching valve for evaporative emissions with the 2 bolts.
9. Install left hand 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 left hand 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.
10. Install right hand 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.
11. Install left hand engine wire cover.
- Connect the portions A and B of the engine wire cover to the wire brackets.
- Set the 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.
12. Install upper high-tension cord cover.
- Fit portion A of the upper high-tension cord cover matching the top of the lower high-tension cord cover.
- Push the front side of the upper high-tension cord cover, and fit the front side claw groove of the upper high-tension cord cover to the claw of the lower high -tension cord cover.
- Install the upper high-tension cord cover with the 2 bolts.
13. 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.
- Install the bolt holding the intake air connector to the cylinder head cover.
- Connect the following hoses:
- Air hose to AC valve (1)
- Air hose from air control valve on power steering pump to intake air connector (2)
14. Connect the following cables to throttle body:
- Accelerator cable (1)
- Transmission throttle control cable (2)
- Cruise control actuator cable (3)
15. Install the throttle body cover and hose clamp with the cap nut and 2 bolts.
- Install the evaporative emissions hose to the hose clamp.
16. Connect negative terminal cable to battery.
17. Fill engine with coolant.
18. Check for fuel leaks.