Installation
PROCEDURE1. Install Injectors And Delivery Pipes.
- Install 2 new grommets to each injector.
- Apply a light coat of spindle oil or gasoline to 2 new 0-rings and install them to each injector.
- While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 6 injectors.
- Position the injector connector outward.
- Place the 4 spacers in position on the intake manifold.
- Place the right hand delivery pipe and No.1 fuel pipe together with the 3 injectors in position on the intake manifold.
- Temporarily install the 2 bolts holding the right hand delivery pipe to the intake manifold.
- Temporarily install the bolt holding the No.1 fuel pipe to the intake manifold.
- Place the left hand delivery pipe and No.2 fuel pipe together with the 3 injectors in position on the intake manifold.
- Connect the fuel return hose to the fuel pressure regulator.
- Temporarily install the 2 bolts holding the left hand delivery pipe to the intake manifold.
- Temporarily install the No.2 fuel pipe to the left hand delivery pipe with the union bolt and 2 new gakets.
- Check that the injectors rotate smoothly.
NOTE: If injectors do not rotate smoothly, the probable cause is incorrect installation of 0-rings. Replace the 0-rings.
- Position the injector connector outward.
- Tighten the 4 bolts holding the delivery pipes to the intake manifold.
Torque: 10 Nm (7 ft lb)
- Tighten the bolt holding the No.1 fuel pipe to the intake manifold.
Torque: 19.5 Nm (14 ft lb)
- Tighten the 2 union bolts holding the No.2 fuel pipe to the delivery pipes.
Torque: 32.5 Nm (24 ft lb)
2. Connect Fuel Inlet And Return Hoses
- Connect the fuel inlet hose to the fuel filter with the 2 new gaskets and union bolt.
Torque: 30 Nm (22 ft lb)
- Connect the fuel return hose to the No.1 fuel pipe.
NOTE: Pass the fuel return hose under the heater hoses.
3. Install Air Assist Hoses And Pipe
- Connect the air assist hoses to the intake manifold.
- Install the air assist pipe to the bracket on the No.1 fuel pipe.
4. Connect Injector Connectors.
5. Install Air Intake Chamber Assembly.
- Using an 8 mm hexagon wrench, install a new gasket and the air intake chamber assembly with the 2 bolts and 2 nuts.
Torque: 43 Nm (32 ft lb)
- Connect the ground strap with the bolt.
- Install the bolt holding the No.1 engine hanger to the air intake chamber.
Torque: 39 Nm (29 ft lb)
- Connect the power steering pressure tube with the nut.
- Connect the following hoses:
Brake booster vacuum hose; 1
Positive Crankcase Ventilation hose; 2
Actuator vacuum hose; 3
Connect the Data Link Connector (DLC) 1; g
Connect the 2 ground straps with the nut; h
Torque: 14.5 Nm (10 ft lb)
- Connect the following hoses:
2 water bypass hoses to throttle body; 1
Air assist hose to throttle body; 2
- Connect the following vacuum hoses:
Vacuum hose to air intake chamber; 1
2 vacuum hoses to throttle body; 2
Vacuum hose to charcoal canister; 3
- Connect the following connectors:
Air conditioning idle-up valve connector; 1
Exhaust Gas Recirculation (EGR) gas temperature sensor connector; 2
Throttle position sensor connector; 3
Idle Air Control (IAC) valve connector; 4
- Install the bolt holding the air intake chamber stay to the air intake chamber.
Torque: 19.5 Nm (14 ft lb)
- Connect the 2 power steering air hoses.
6. Connect Hydraulic Motor Pressure Pipe Connect the pressure pipe to the air intake chamber and water inlet with the 2 bolts.
Torque: 8 Nm (69 in lb)
7. Install No.2 Egr Pipe.
- Install 2 new gaskets and the EGR pipe with the 4 nuts.
Torque: 12 Nm (9 ft lb)
8. Install Emission Control Valve Set.
- Install the emission control valve set with 2 bolts.
Torque: 8 Nm (69 in lb)
- Connect the following connectors:
Vacuum Switching Valve (VSV) connector for Acoustic Control Induction System (ACIS); 1
VSV connector for EGR; 2
VSV connector for fuel pressure control; 3
- Connect the following vacuum hoses:
Vacuum hose to VSV for ACIS; 1
Vacuum hose to EGR vacuum modulator; 2
Vacuum hose to EGR valve; 3
Vacuum hose (from cylinder head rear plate); 4
Vacuum hose from air intake chamber; 5
Vacuum hose to fuel pressure regulator; 6
9. Install V-bank Covers.
- Using a 5 mm hexagon wrench. install the V-bank cover with the 2 cap nuts.
NOTE: When installing the V-bank cover, push on the cover until a "click" is felt.
10. Install Air Cleaner Hose.
- Connect the air cleaner hose with the 2 hose clamps.
- Connect the PCV hose.
11. Connect Throttle Cable.
12. Connect Accelerator Cable.
13. Fill With Engine Coolant.
Capacity: 8.7 liters (9.2 US qts)
14. Connect Negative (-) Terminal Cable To Battery.