Installation

Air Intake Chamber And Related Parts:

Fuel Rail Assembly:

COMPONENTS FOR INSTALLATION

INJECTORS INSTALLATION

1. Install injectors and delivery pipe.




(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to a new O-ring and install it to the injector.




(c) While turning the injector left and right, install it to the delivery pipe. Install the 6 injectors.
(d) Position the injector connector upward.




(e) Place 6 new insulators and the 3 spacers in position on the intake manifold.
(f) Place the 6 injectors together with the delivery pipe in position on the intake manifold.




(g) Temporarily install the 3 bolts holding the delivery pipe to the intake manifold.




(h) Check that the injectors rotate smoothly.

HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.

(i) Position the injector connector upward.
(j) Tighten the 3 bolts holding the delivery pipe to the intake manifold.

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)




(k) Connect the 6 injector connectors as shown.




2. Install fuel in let pipe.
Install the fuel inlet pipe with 4 new gaskets, the 2 union bolts and bolt.

Torque:
Union bolt: 29 N.m (300 kgf.cm, 22 ft.lbf)
Bolt: 20 N.m (200 kgf.cm, 14 ft.lbf)




3. Install fuel return pipe.
(a) Install the fuel return pipe with the 2 bolts.

Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)

(b) Connect the fuel hose to the fuel pressure regulator.




4. Install air intake chamber.
Install 2 new gaskets and the air intake chamber with the 6 bolts and 2 nuts.

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)





5. Connect no. 1 water bypass hose to cylinder head.
6. Connect vacuum hoses to TVV.




7. Install intake manifold stay.
Install the intake manifold stay with the 2 bolts.

Torque: 36 N.m (360 kgf.cm, 26 ft.lbf)




8. Connect ground strap.
9. Install engine oil dipstick.
10. Connect PS reservoir tank.
Connect the reservoir tank with the 3 bolts.

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




11. Connect EGR gas temp. sensor connector.
12. Connect connector for emission control valve set assembly.
13. Connect idle air control valve connector.
14. Connect throttle position sensor connector.




15. Connect brake booster hose.
16. Connect EVAP hose.
17. Connect no. 2 water bypass hose.
18. Connect vacuum sensing hose.
19. Connect no. 1 PCV hose.




20. Install bolt holding heater inlet pipe and air intake chamber.

Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)

21. Install EGR valve and vacuum modulator.
22. Connect throttle cable.
23. Connect accelerator cable.
24. Connect cruise control actuator cable.
25. Connect air cleaner hose.
26. Connect no. 2 PCV hose.
27. Fill with engine coolant.