Part 2

21. Install accelerator, A/T throttle control cables and bracket.
a. Install the cable bracket to the intake manifold with the 2 bolts.
b. Install the control cables to the 4 clamps.
22. Connect PCV hose to intake manifold.

3. California: Install Vacuum Switching Valve (VSV) assembly for fuel pressure control and EGR.
a. Install the VSV assembly with the bolt.
b. Connect the 2 VSV connectors.

24. Except California: Install VSV for EGR.
a. Install the VSV with the bolt.
b. Connect the VSV connector.

25. Connect knock sensor connector.
26. Install the ground cable with the bolt.

27. Except California: Install vacuum pipe.
a. Install the vacuum pipe with the bolt.
b. Connect the following hoses:
(1) Vacuum sensing hose to gas filter on intake manifold
(2) Vacuum sensing hose to fuel pressure regulator

28. Install air tube.
a. Install the air tube and hose bracket (for EGR) with the 2 bolts.

b. Connect the following hoses:
(1) California only: 2 vacuum sensing hoses to VSV for fuel pressure control
(2) 2 PS air hoses to air tube

(3) PS air hose to intake manifold
(4) California only: Vacuum sensing hose to fuel pressure regulator

29. Install the A/T throttle control cable to the clamp on the rear side of the intake manifold.

30. Install the intake manifold stay with the bolt and nut.
Torque:
Bolt 21 Nm (15 ft lb)
Nut 44 Nm (32 ft lb)

31. Install EGR valve and vacuum modulator.
a. Install a new gasket and the EGR valve with the union nut and 2 nuts.
Torque:
Nut 13 Nm (9 ft lb)
Union bolt 59 Nm (43 ft lb)
b. Install the vacuum modulator to the clamp on the intake manifold.

c. Connect the 2 vacuum hoses to the VSV for the EGR.

d. Install the hose clamp to the bracket on the air tube.

e. Connect the EGR gas temperature sensor connector, and install the sensor connector to the bracket on the intake manifold.
f. Connect the Evaporative Emission (EVAP) hose to the charcoal canister.

32. Install A/C idle-up valve.
a. Install the idle-up valve with the 2 bolts.

b. Connect the following connector and hoses:
(1) Idle-up valve connector.
(2) Air hose to intake manifold.
(3) Air hose to air tube.

33. Connect the following hoses:
(1) Vacuum sensor hose to gas filter on intake manifold
(2) Brake booster vacuum hose to intake manifold

34. Install throttle body.
a. Attach a new gasket to the throttle body, facing the protrusion downward.

b. Type A: Install the throttle body with the 4 bolts.
Torque: 19 Nm (14 ft lb)

NOTE: Different bolt lengths are used for the upper and lower sides.
Bolt length:
Upper side 45 mm (1.77 in.)
Lower side 55 mm (2.17 in.)
c. Type B: Install the throttle body with the 2 bolts and 2 nuts.
Torque: 19 Nm (14 ft lb)

d. Connect the following hoses:
(1) Vacuum hose (from upper port of Thermal Vacuum Valve (TVV) for EVAP) to port "P of throttle body.
(2) Vacuum hose (from port -0- of EGR vacuum modulator) to port "E" of throttle body.
(3) Vacuum hose (from port "R" of EGR vacuum modulator) to port "R" of throttle body.
(4) PCV hose (from cylinder head) to throttle body.
(5) California: Air hose for air assist system to Idle Air Control (IAC) valve.
(6) Except California: Air hose for A/C and PS idle-up to IAC valve.

e. Connect the following connectors:
(1) Throttle position sensor connector.
(2) IAC valve connector.

f. Connect the following cables to the throttle body:
(1) Accelerator cable
(2) A/T throttle control cable

35. Install water by-pass pipe.
a. Install a new gasket to the water pump cover.
b. Install a new O-ring to the bypass pipe.
c. Apply soapy water on the O-ring.
d. Connect the water bypass pipe to the water pump cover.

e. Install the bypass pipe with the 2 nuts and 2 bolts.
Torque:
Nut 9.3 Nm (82 in. lb)
Bolt 19 Nm (14 ft lb)

f. Connect the following hoses:
(1) IAC valve water bypass hose to water bypass pipe
(2) Heater water hose to water bypass pipe
(3) 2 oil cooler water bypass hoses to oil cooler

g. Install the oil cooler heat protector with the 2 nuts and bolt.

36. Install water outlet.
a. Install a new gasket, the water outlet and outlet housing with the 2 nuts.
Torque: 15 Nm (11 ft lb)

b. Connect the following hoses to the water outlet:
(1) Radiator hose.
(2) Water bypass pipe hose.
(3) Heater water hose.
(4) Vacuum hose (from P port of throttle body) to upper port of TVV for EVAP.
(5) Vacuum hose (from charcoal canister) to lower port of TVV for EVAP.
(6) IAC valve water bypass hose

c. Connect the following connectors:
(1) Engine Coolant Temperature (ECT) sensor connector
(2) ECT sender gauge connector
37. Connect oil pressure switch connector.

38. Assemble exhaust manifold and Three-Way Catalytic Converter (TWC) (front).If previously separated.
a. Place the cushion, retainer and a new gasket on the TWC.
b. Install the TWC to the exhaust manifold with the 3 bolts and 2 nuts.
Torque: 29 Nm (22 ft lb)

c. Install the lower manifold heat insulator with the 5 bolts.
d. Install the 2 TWC heat insulators with the 8 bolts.

39. Install a new gasket and the main oxygen sensor with 2 new nuts.
Torque: 20 Nm (14 ft lb)

40. California only: Install sub oxygen sensor to front TWC.
Torque: 44 Nm (33 ft lb)

41. Install exhaust manifold and TWC (front) assembly.
a. Install a new gasket. the exhaust manifold and TWC assembly with the 6 nuts. Uniformly tighten the nuts in several passes.
Torque: 49 Nm (36 ft lb)

b. Install the RH exhaust manifold stay with the 2 bolts and 2 new nuts.
Torque: 42 Nm (31 ft lb)

c. Install the upper manifold heat insulator with the 5 bolts.

d. Install the LH exhaust manifold stay with the bolt and nut.
Torque:
Bolt 39 Nm (29 ft lb)
Nut 42 Nm (31 ft lb)

e. Connect the following connectors:
(1) Oxygen sensor (main) connector
(2) California only: Sub oxygen sensor connector

42. Install front exhaust pipe.
a. Place 2 new gaskets to the front and rear of the front exhaust pipe.
b. Temporarily install the 2 bolts and 2 new nuts holding the front exhaust pipe to the rear TWC/center exhaust pipe.
c. Temporarily install 3 new nuts holding the front exhaust pipe to the TWC (front).
d. Temporarily install the 2 bolts holding the front exhaust pipe to the exhaust pipe support bracket.
e. Using a 14 mm deep socket wrench. tighten the 3 nuts holding the front exhaust pipe to the TWC (front).
Torque: 62 Nm (46 ft lb)
f. Tighten the 2 bolts and nuts holding the front exhaust pipe to the rear TWC/center exhaust pipe.
Torque: 43 Nm (32 ft lb)
g. Tighten the 2 bolts holding the front exhaust pipe to the exhaust pipe support bracket.
Torque: 19 Nm (14 ft lb)

43. Install generator.
a. Install the generator with the pivot bolt and adjusting lock bolt (with A/C) or adjusting bolt (with out A/C). Do not tighten the bolts yet.

b. Install the drive belt with the pivot bolt, adjusting lock bolt (with A/C) and adjusting bolt.
c. Adjust the drive belt.
d. Tighten the pivot bolt, adjusting lock bolt (with A/C) and adjusting bolt (with out A/C).
Torque:
Pivot bolt 54 Nm (40 ft lb)
Adjusting lock bolt (with A/C) or
adjusting bolt (with out A/C) 19 Nm (14 ft lb)

e. Connect the generator connector.
f. Connect the generator wire with the nut and rubber cap.
g. Install the wire to the clamp on the rear end cover.

44. Install distributor.

45. Install air cleaner.
a. Install the air cleaner case with the 3 bolts.
b. Install the 2 engine wires to the clamps on the air cleaner case.
c. Install the air filter.

d. Connect the air cleaner hose to the throttle body.
e. Install the air cleaner cap to the air cleaner case with the 4 clamps.
f. Tighten the hose clamp.
g. Connect the following connector, cord, cables and hoses:
(1) Intake Air Temperature (IAT) sensor connector.
(2) California only: High-tension cord to air cleaner hose.
(3) Accelerator cable to clamp
(4) Cruise control actuator cable to clamps
(5) California only: Air hose for idle-up to air cleaner hose
46. Fill with engine coolant.
47. Connect negative (-) terminal cable to battery.
48. Start engine and check for leaks.
49. Perform engine adjustment.
50. Perform road test. Check for abnormal noises, shock, slipage, correct shift points and smooth operation.
51. Recheck engine coolant level,engine oil and transaxle fluid levels.