Replacement

REPLACEMENT

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DRAIN ENGINE COOLANT
3. SEPARATE BATTERY NEGATIVE TERMINAL
4. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY
a. Remove the 2 nuts and throttle body cover sub-assembly.

5. REMOVE AIR CLEANER HOSE ASSEMBLY
6. DISCONNECT FUEL HOSE
7. DISCONNECT FUEL HOSE NO.2
8. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY
9. SEPARATE ENGINE WIRE
a. Disconnect the 8 fuel injector connectors.
b. Disconnect the throttle position sensor connector.
c. Disconnect the water temperature sensor connector.
d. Remove the 3 bolts and separate the engine wire harness.

10. DISCONNECT WATER BY-PASS HOSE NO.7
11. DISCONNECT WATER BY-PASS HOSE
12. REMOVE INTAKE MANIFOLD ASSEMBLY
a. Remove the 6 bolts and 4 nuts.
b. Remove the intake manifold assembly and 2 gaskets.

13. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Separate the engine wire No.2.
b. Remove the nut and water by-pass pipe sub-assembly.

14. REMOVE WATER BY-PASS JOINT RR
a. Remove the 4 nuts, water by-pass joint and 2 gaskets.

15. REMOVE AIR PUMP ASSEMBLY W/ BRACKET




16. REMOVE STARTER ASSEMBLY
a. Disconnect the starter connector.
b. Remove the nut and disconnect the starter cable.
c. Remove the bolt and disconnect the engine wire protector.
d. Remove the 2 bolts and starter.

17. INSTALL STARTER ASSEMBLY
a. Install the starter assembly with the 2 bolts.

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

b. Connect the engine wire protector with the bolt.
c. Connect the starter cable with the nut.

Torque: 9.8 N.m (100 kgf.cm, 86 in.lbf)

d. Connect the starter connector.

18. INSTALL AIR PUMP ASSEMBLY W/ BRACKET
19. INSTALL WATER BY-PASS JOINT RR
a. Install 2 new gaskets to the cylinder head.
b. Install the 4 nuts holding the water by-pass joint to the cylinder leads. Alternately tighten the nuts.

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

20. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring.
c. Push the water by-pass pipe end into the pipe hole of the water pump.
d. Install the water by-pass pipe with the bolt.

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

e. Install the wire clamp to the bracket of the water by-pass pipe.

21. INSTALL INTAKE MANIFOLD ASSEMBLY
a. Instal 2 new gaskets to the cylinder head.
b. Install the intake manifold assembly with the 6 bolts and 2 nuts.

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

22. CONNECT WATER BY-PASS HOSE
23. CONNECT WATER BY-PASS HOSE NO.7
24. INSTALL ENGINE WIRE

Torque: 8.2 N.m (83 kgf.cm, 72 in.lbf)

25. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
26. CONNECT FUEL HOSE NO.2
27. CONNECT FUEL HOSE
28. INSTALL AIR CLEANER HOSE ASSEMBLY
29. REFILL ENGINE COOLANT
30. CHECK FOR ENGINE COOLANT LEAKS
31. INSPECT FOR FUEL LEAKS
32. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY

Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)