INTAKE MANIFOLD INSTALLATION

INSTALL INTAKE MANIFOLD
1. Install the wire harness clamp bracket with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Text in Illustration
  
  *a Black
  
  Connect the 2 vacuum hoses and check that the No. 1 check valve is installed as shown in the illustration.
3. Check the tumble control valves (w/ TCV).
  
  Note
  
  The tumble control valves may be damaged if they are not closed before installing the intake manifold.
  
  Tech Tips
  
  Connect the battery to the terminals of the actuator to operate the motor and close the valves Click here.
4. Install a new intake manifold gasket to the intake manifold.
5. Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration (w/ TCV).
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
6. Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration (w/o TCV).
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
7. Connect the intake air control actuator connector and 2 wire harness clamps (w/ TCV).
8. Connect the 2 wire harness clamps (w/o TCV).
9. Install the wire harness clamp with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Text in Illustration
  
  *A w/ TCV
  
  *B w/o TCV
10. Install the wire harness clamp bracket with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
11. Connect the 3 wire harness clamps and connector.
12. Connect the fuel vapor feed hose.
13. Install the 2 wire harness clamp brackets with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }

Text in Illustration
*a	Black

Text in Illustration
*A	w/ TCV
*B	w/o TCV

INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Text in Illustration
*1	Fuel Delivery Spacer
*2	Injector Vibration Insulator
*a	Fuel Delivery Pipe Sub-assembly Side
*b	Cylinder Head Side

Install 4 new injector vibration insulators to the cylinder head.

Install the 2 fuel delivery spacers to the cylinder head.

Tech Tips

Install the fuel delivery spacer so that the longer protrusion is on the cylinder head side.
Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies with the 2 bolts.

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Note
- Do not drop the fuel injector assemblies when installing the fuel delivery pipe sub-assembly.
- Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly.

CONNECT FUEL TUBE SUB-ASSEMBLY

Text in Illustration
*a	Retainer
*b	O-ring
*c	Fuel Tube Connector
*d	Fuel Pipe
*e	Nylon Tube

Connect the fuel tube sub-assembly to the fuel pipe.

Note

Check if there is any damage or foreign matter on the connecting parts of the fuel lines.

Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.
After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

Engage the claw and install the No. 1 fuel pipe clamp.
Engage the clamp to connect the fuel tube sub-assembly to the fuel hose clamp.

CONNECT UNION TO CONNECTOR TUBE HOSE
1. Connect the union to connector tube hose to the intake manifold.
CONNECT NO. 2 VENTILATION HOSE
1. Connect the No. 2 ventilation hose to the intake manifold.
INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
1. Install the vacuum switching valve assembly with the bolt.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
2. Connect the 2 vacuum hoses and connector.
3. Connect the union to connector tube hose and wire harness clamp.
INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

Click here
INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)
1. Install the front outer cowl top panel sub-assembly with the 10 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.
INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)
1. Install the front outer cowl top panel sub-assembly with the 10 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.
3. w/ Windshield Deicer System:
  1. Connect the connector.
  2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.
4. w/ Heated Windshield Defroster System:
  1. Connect the 2 connectors.
  2. Engage the 4 clamps to install the wire harness to the front outer cowl top panel sub-assembly.
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here
CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Click here
INSPECT FOR FUEL LEAK
1. Check fuel pump operation.
  1. Connect the intelligent tester to the DLC3.
  2. Turn the ignition switch to ON and turn the intelligent tester on.
    
    Note
    
    Do not start the engine.
  3. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.
  4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.
2. Inspect for fuel leaks.
  1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.
3. Turn the ignition switch off.
4. Disconnect the intelligent tester from the DLC3.