Installation
PROCEDURE1. Reinstall knock sensors.
- Using SST. reinstall the 2 knock sensors. (SST 09816-30010)
Torque: 39 Nm (29 ft lbf)
- Connect the 2 knock sensor connectors.
2. Reinstall delivery pipe and intake manifold assembly.
- Place 2 new gaskets on the cylinder heads with the white painted mark facing upward.
NOTE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction.
- Place the delivery pipes and intake manifold assembly in position on the cylinder heads with the arrow mark on the intake manifold facing forward.
NOTE: Be careful of the installation direction.
- Install the 6 bolts and 4 nuts.
Torque: 18 Nm (13 ft lb)
NOTE: Use bolts 30 mm (1.18 in) in length.
3. Install the return pipe with 2 new gaskets, union bolt and bolt.
Torque: 35 Nm (26 ft lb) for union bolt
4. Tighten lock nut on fuel pressure regulator.
Torque: 29 Nm (22 ft lb)
Engine Wire Connectors:
5. 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.
Engine Wiring Harness:
- 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.
6. Install engine wire to intake manifold with the 2 bolts.
7. Temporarily install exhaust gas recirculation pipe to right hand cylinder head with the bolt.
8. 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.)
9. 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.
10. 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)
11. 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.
12. 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)
- 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)
13. 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.
14. 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.
15. Install vacuum switching valve for evaporative emissions with the 2 bolts.
16. 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.
17. 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.
18. 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.
19. 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.
20. 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)
21. Connect the following cables to throttle body:
- Accelerator cable (1)
- Transmission throttle control cable (2)
- Cruise control actuator cable (3)
22. Install the throttle body cover and hose clamp with the cap nut and 2 bolts.
- Install the evaporative emissions hose to the hose clamp.
23. Connect negative terminal cable to battery.
24. Fill engine with coolant.
25. Check for fuel leaks.