Installation Steps

INSTALL INJECTORS ONTO DELIVERY PIPE
1. FOR HELP WITH INJECTOR REMOVAL REFER TO REMOVAL PROCEDURES.

2. INSTALL INJECTORS.
(a) Apply a light coat of gasoline to 2 new 0-rings.



(b) Install the 2 0-rings and new insulator to each injector.



(c) Push in the 6 injectors so that the injector connectors are positioned as shown in the illustration.



INSTALLATION OF INJECTORS AND DELIVERY PIPE
1. INSTALL INJECTORS AND DELIVERY PIPE.



(a) Install the 2 spacers to the intake manifold.



(b) Install 6 new insulators to the delivery pipe.



(c) Attach the delivery pipe to the intake manifold.
(d) Install the delivery pipe with the 2 bolts.

Torque: 21 Nm (15 ft.lb)




(e) Install 6 new insulators to the injectors.



(f) Install the 3 injector holders with the 6 bolts.

Torque: 7.8 Nm (69 in.lb)

2. CONNECT FUEL INLET PIPE TO DELIVERY PIPE.



Connect the inlet pipe with 2 new gaskets and the union bolt.

Torque: 41 Nm (30 ft.lb)

3. CONNECT FUEL RETURN PIPE TO FUEL PRESSURE REGULATOR.
Connect the return pipe with 2 new gaskets and the union bolt.

Torque: 27 Nm (20 ft.lb)

4. CONNECT CONNECTORS AND WIRE CLAMPS.
Connect the following connectors and clamps:



(1) 6 injectors connectors

HINT: The No. 1, No. 3 and No. 5 injector connectors are Dark Gray. The No. 2, No. 4 and No. 6 injector connectors are Gray.

(2) 2 camshaft position sensor connectors
(3) 3 engine wire clamps to injector holders

5. INSTALL AIR INTAKE CHAMBER ASSEMBLY.



(a) Install a new gasket to the intake manifold.
(b) Connect the water bypass hose to the IAC valve.



(c) Install the air intake chamber assembly and engine wire bracket with the 5 bolts and 2 nuts.

Torque: 27 Nm (20 ft.lb)





(d) Attach the 2 clamps of the engine wire protector to the brackets.
(e) Install the engine wire protector with the 2 bolts.
(f) Install the ground wire with the bolt.

6. INSTALL MANIFOLD STAY.



Install the manifold stay with the 2 bolt.

Torque: 39 Nm (29 ft.lb)

7. INSTALL NO. 4 WATER BYPASS PIPE.
Install the No. 4 water bypass pipe with the 2 bolts.

8. INSTALL EGR PIPE.



(a) Temporarily connect the EGR pipe to the EGR valve with union nut.
(b) Install a new gasket and the EGR pipe to the cylinder head with the 2 bolts.

Torque: 21 Nm (15 ft.lb)

(c) Tighten the union nut holding the EGR pipe to the EGR valve.

Torque: 64 Nm (47 ft.lb)

9. INSTALL EGR GAS TEMPERATURE SENSOR CONNECTOR.
(a) Connect the EGR gas temperature sensor connector to the wiring connector.
(b) Install the sensor connector to the bracket on the air intake chamber.

10. CONNECT HOSES AND CONNECTORS.
(a) Connect the following hoses:



(1) Air hose to IAC valve
Connect the air hose to the IAC valve, and attach the IAC valve pipe to the clamp on the cylinder head cover.
(2) Air hose (from air intake chamber) to vacuum pipe on IAC valve pipe
(3) Air hose for EGR to valve pipe



(4) PCV hose to PCV valve
(5) Vacuum sensing hose to fuel pressure regulator



(6) Water bypass hose (from IAC valve) to No. 4 water bypass pipe
(7) EVAP hose (from air intake chamber) to vacuum pipe on manifold stay
(8) EVAP hose (from vacuum pipe on No. 4 water bypass pipe) to No. 2 vacuum pipe
(9) EVAP hose (from charcoal canister) to No. 2 vacuum pipe
(10) PS air hose to air intake chamber
(11) Brake booster vacuum hose to union on air intake chamber



(b) Install the engine wire protector with the bolt.

(c) Connect the following connectors:



(1) IAC valve connector
(2) Turbo pressure sensor connector
(3) VSV connector for fuel pressure control
(4) VSV connector for EGR

11. INSTALL CONTROL CABLE BRACKET AND CABLES.



Install the control cable bracket and cables with the 2 bolts.

Torque: 19 Nm (14 ft.lb)

12. INSTALL AIR INTAKE CHAMBER STAY.
Install the chamber stay with the bolt and nut.

Torque: 19 Nm (14 ft.lb)

13. INSTALL OIL DIPSTICK GUIDE FOR ENGINE.



(a) Install a new 0-ring on the dipstick guide.
(b) Apply soapy water on the 0-ring.
(c) Connect the dipstick guide end to the oil pan.
(d) Install the dipstick guide with the bolt.
(e) Install the fuel return hose to the clamp of the dipstick guide.

14. INSTALL OIL DIPSTICK GUIDE FOR A/T.



(a) Install a new 0-ring on the dipstick guide.
(b) Apply soapy water on the 0-ring.
(c) Connect the dipstick guide end to the oil pan.
(d) Install the dipstick guide with the bolt.

15. INSTALL THROTTLE BODY.
(a) Connect the following hoses to the throttle body:



(1) EVAP hose
(2) Water bypass hose (from No. 4 water bypass pipe)
(3) Water bypass hose (from cylinder head)
(4) PS air hose



(b) Install a new gasket to the air intake chamber.
(c) Install the throttle body with the 2 bolts and 2 nuts.

Torque: 21 Nm (15 ft.lb)

(d) Connect the following hose, cables and connectors to the throttle body:



(1) Air hose
(2) Accelerator cable
(3) Cruise control actuator cable
(4) Throttle position sensor connector
(5) Sub-throttle position sensor connector
(6) Sub-throttle actuator connector

16. FILL WITH ENGINE COOLANT.
17. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY.
18. CHECK FOR FUEL LEAKS.
Refer to "Checking the Fuel System For Leaks" under Service and Repair.
Service and Repair
19. INSTALL ENGINE UNDER COVER.