Installation
1. Install intake manifold assembly as follows:
(a) Place two new gaskets on the cylinder heads with white painted mark facing upward.
NOTE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction.
(b) Place the intake manifold on the cylinder heads with the arrow mark facing forward.
NOTE: Be careful of the installation direction.
(c) Install and uniformly tighten the six bolts and four nuts in several passes to 18 Nm (185 kg.cm, 13 ft.lb).
NOTE: Use a bolt 30 mm (1.18 in) in length.
(d) Connect the eight injector connectors.
2. Install the fuel return pipe with the two bolts, then connect the fuel hose to the fuel pressure regulator.
3. Install engine wire to delivery pipe and rear water bypass joint as follows:
(a) Install these connectors:
- DLC1 to connector bracket on LH delivery pipe (1).
- 2 engine wire connectors to connector bracket on LH delivery pipe (2).
- Engine wire clamp to wire bracket on LH delivery pipe (3).
(b) Install the engine wire protector to the RH delivery pipe with the two bolts.
(c) Install the engine wire protector to the rear water bypass joint with the two bolts.
(d) Install the A/T throttle cable to the clamps on the engine wire protector and engine hanger.
3. Connect fuel return hose to fuel return pipe.
4. Connect fuel inlet hose to LH delivery pipe, refer to Powertrain Management.
5. Install air intake chamber assembly as follows:
(a) Place four new gaskets on the intake manifold.
NOTE: Gaskets can only be used twice before being replaced.
(b) Connect these hoses, and place the air intake chamber assembly on the intake manifold:
- PCV hose (from RH cylinder head) to throttle body (1).
- Water bypass hose (from Idle Air Control (IAC) valve) to water inlet housing (2) .
(c) Install the air intake chamber, Vacuum Switching Valve (VSV) for fuel pressure control (1) and VSV for EVAP (2) with the four bolts and eight nuts, then uniformly tighten the bolts and nuts several passes to 18 Nm (185 kg.cm, 13 ft.lb).
NOTE: Use bolt 40 mm (1.57 in) in length.
(d) Install two new gaskets and No.2 EGR pipe with the two bolts and two nuts, tighten to 22.5 Nm (230 kg.cm, 17 ft.lb).
NOTE: Use bolt 20 mm (0.79 in) in length.
(e) Connect the heater hose to the water bypass pipe.
(f) Connect these hoses:
- Brake booster vacuum hose (1) to union on air intake chamber.
- PCV hose to PCV valve (2) on LH cylinder head.
- Water bypass hose from EGR valve (3) to rear water bypass joint.
- Water bypass hose from throttle body (4) to rear water bypass joint.
- Vacuum hose from VSV for fuel pressure control (5) to fuel pressure regulator.
- EVAP hose from charcoal canister (6) to VSV for EVAP
(g) Connect these connectors:
- Throttle position sensor connector with Traction Control System (TRAC).
- Sub-throttle position sensor connector w/ TRAC.
- Sub-throttle actuator connector IAC valve connector.
- EGR valve connector.
- EGR gas temperature sensor connector.
- VSV connector for fuel pressure control.
- VSV connector for EVAP.
(h) Install the accelerator bracket with the two bolts.
(i) Connect these cables:
- Accelerator cable.
- A/T throttle control cable.
- Cruise control actuator cable.
6. Install timing belt rear plates tighten to 7.5 in m (80 kg.cm, 66 inch lbs.).
7. Install the No.2 ignition coil with the two bolts, then connect the ignition coil connector.
8. Install high-tension (spark plug wires) cords, cord clamps and cord cover assembly as follows:
(a) Connect the high-tension cords to the spark plugs, distributor caps and No.2 ignition coil.
(b) Install the lower high-tension cord cover with the stud bolt.
(c) Connect the RH front high-tension cord clamp to the lower high-tension cord cover.
(d) Place the RH front high-tension cord clamp to the RH rear high-tension cord clamp.
(e) Install the two bolts holding the RH high-tension cord clamps to the RH cylinder head cover.
(f) Connect the No.2 high-tension cord to the cord clamp on the RH front high-tension cord clamp.
(g) Connect the LH front high-tension cord clamp to the lower high-tension cord cover.
(h) Place the LH front high-tension cord clamp to the LH rear high-tension cord clamp.
(i) Install the two bolts holding the LH high-tension cord clamps to the LH cylinder head cover.
(j) Connect the No.1 high-tension cord to the cord clamp on the LH front high-tension cord clamp.
9. Install a new gasket and the front TWC with three new nuts tighten to 61.8 Nm (630 kg.cm, 46 ft.lb).
10. Connect front exhaust pipe to front TWC as follows:
(a) Install the pipe support bracket to the transmission with the two bolts hand tight.
(b) Install a new gasket to each front end of the front exhaust pipe.
(c) Connect the front exhaust pipe to the two front TWC with the four bolts and four new nuts, tighten to 44 Nm (440 kg.cm, 32 ft.lb).
(d) Tighten the two bolts holding the pipe support bracket to the transmission to 44 Nm (440 kg.cm, 32 ft.lb).
11. Install the Power Steering (PS) pump with the three bolts and the nut, then alternately tighten bolts to 39 Nm (400 kg.cm, 29 ft. lbs) and the nut to 43 Nm (440 kg.cm, 32 ft.lb).
12. Connect the PS air hose to the air intake chamber.
13. Install camshaft timing pulleys.
14. Connect timing belt to camshaft timing pulleys.
15. Check engine oil level.