Installation

INSTALLATION OF STARTER

Starter Components For Removal And Installation:

1. INSTALL STARTER
(a) Connect the wire clamp to the wire bracket.
(b) Connect the starter wire with the nut.
(c) Connect the starter connector.






(d) Install the starter with the two bolts.

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






2. INSTALL REAR WATER BY-PASS JOINT
(a) Install four new gaskets and the water by-pass joint with the four nuts.

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

(b) Install the bolt holding the water by-pass pipe to the LH engine hanger.






3. INSTALL WATER BY-PASS PIPE
(a) Install a new 0-ring to the water by-pass pipe.
(b) Apply soapy water to the 0-ring.
(c) Push in the water by-pass pipe end into the pipe hole of the water pump.
(d) Install the water by-pass pipe with the two bolts.

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






4. CONNECT HEATER WATER HOSES TO WATER BY-PASS PIPE AND REAR WATER BY-PASS JOINT






5. INSTALL DELIVERY PIPES AND INTAKE MANIFOLD ASSEMBLY
(a) Place two new gaskets on the cylinder heads with the white painted mark facing upward.

NOTICE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction.






(b) Place the delivery pipes and intake manifold assembly in position on the cylinder heads with the arrow mark on the intake manifold facing forward.

NOTICE: Be careful of the installation direction.

(c) Install the six mounting bolts and four mounting nuts.

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

HINT: Use bolts 30 mm (1.18 in.) in length.






6. INSTALL FUEL RETURN PIPE
Install the return pipe with two new gaskets, union bolt and bolt.

Torque (Union bolt): 35 N.m (360 kgf.cm, 26 ft.Ibf)






7. INSTALL ENGINE WIRE TO DELIVERY PIPES, REAR WATER BY-PASS JOINT AND RH CYLINDER HEAD
(a) Connect the eight injector connectors.
(b) Connect the two engine wire connectors to the connector bracket on the LH delivery pipe.






(c) Install the engine wire to the RH cylinder head with the two bolts.
(d) Install the engine wire to the rear water by-pass joint with the two bolts.
(e) Install the engine wire to the delivery pipes with the four bolts.






8. INSTALL ENGINE WIRE TO INTAKE MANIFOLD
Install the engine wire with the two bolts.






9. TEMPORARILY INSTALL EGR PIPE TO RH CYLINDER HEAD
Temporarily install the EGR pipe with the bolt.
10 CONNECT FUEL RETURN HOSE TO FUEL RETURN PIPE






11. CONNECT FUEL INLET HOSE TO LH DELIVERY PIPE
Using SST, connect the inlet hose with two new gaskets and pulsation damper. SST 09612-24014 (09617-24011)

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 33 N.m (340 kgf.cm, 24 ft.lbf) for SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).







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






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






(c) (Exc. USA Spec.)
Install the connector bracket to check ("DIAGNOSIS") connector.
(d) Install the air intake chamber and following parts with the four bolts and eight nuts:
(1) Check ("DIAGNOSIS") connector
(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.Ibf)

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






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

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
(f) Tighten the bolt holding the EGR pipe to the RH cylinder head.

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






(g) 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.lbf)






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






13. CONNECT HOSES
Connect the following hoses:
(1) Water by-pass (from EGR valve) to water bypass 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






(5) Water by-pass hose (from water inlet housing) to ISC 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.

14. CONNECT CONNECTORS
Connect the following connectors:
- Cold start injector connector
- ISC valve connector

- (USA Spec.)
EGR valve connector

- (Exc. USA Spec.)
VSV connector for EGR system
VSV connector for fuel pressure control system






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






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

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

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.






(d) Connect the following hoses:
(1) Water by-pass hose to the ISC valve
(2) (USA Spec.)
Vacuum hose to throttle body
(3) (Exc. USA Spec.)
Three vacuum hoses to throttle body






(4) Heater water hose to heater water valve






(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






16. 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.






17. INSTALL RH NO.3 TIMING BELT COVER
(a) Install the three gaskets 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.






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






19. 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.






20 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.






21. 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.






22. 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.






23. 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.






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






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






25. INSTALL THROTTLE BODY COVER
Install the throttle body cover and hose clamp with the two bolts and cap nut.
26. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
27. FILL WITH ENGINE COOLANT
- Use a good brand of ethylene-glycol base coolant, mixed according to the manufacture's direction. Use coolant which includes more than 50% ethylene-glycol (But not more than 70%) ethylene-glycol is recommended. Do not use alcohol type coolant. The coolant should be mixed with demineralized water or distilled water.
28. CHECK THAT ENGINE STARTS