INTAKE MANIFOLD INSTALLATION

INSTALL INTAKE MANIFOLD
1. Install the wire harness clamp bracket to the intake manifold with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Text in Illustration
  
  *a Black
  
  Connect the 2 vacuum hoses to the intake manifold to install the No. 1 check valve.
  
  Tech Tips
  
  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 intake air control valve actuator to operate the motor and close the tumble control 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:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
6. Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration (w/o TCV).
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
7. Text in Illustration
  
  *A w/ TCV
  
  *B w/o TCV
  
  Connect the intake air control valve actuator connector and engage the 2 wire harness clamps (w/ TCV).
8. Engage the 2 wire harness clamps (w/o TCV).
9. Install the wire harness with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
10. Install the wire harness clamp bracket to the intake manifold with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
11. Connect the wire harness connector.
12. Engage the 3 wire harness clamps.
13. Connect the fuel vapor feed hose to the intake manifold and slide the clip to secure it.
14. Install the 2 wire harness clamp brackets to the intake manifold with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }

Text in Illustration
*a	Black

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

INSTALL FUEL DELIVERY PIPE

Text in Illustration
*1	Fuel Delivery Spacer
*a	Fuel Delivery Pipe Side
*b	Cylinder Head Side

Install 4 new injector vibration insulators to the cylinder head.

Install the 2 fuel delivery spacers onto 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 with the 4 fuel injector assemblies and install 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.
- Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe.

CONNECT FUEL TUBE SUB-ASSEMBLY

Text in Illustration
*1	Fuel Pipe
*2	Fuel Tube Connector
*3	Nylon Tube
*4	O-ring
*5	Retainer

Push the fuel tube connector to the fuel pipe until the fuel tube connector makes a "click" sound.

Note

Before connecting the fuel tube connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe.
After connecting the fuel tube connector and fuel pipe, check that they are securely connected by trying to pull them apart.

Install the No. 1 fuel pipe clamp.
Connect the fuel tube sub-assembly to the fuel hose clamp.

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

Click here
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. Connect the connector to install the wire harness to the front outer cowl top panel sub-assembly.
4. Engage the 2 clamps (B).
5. w/ Wiper Deicer System:
  
  Engage the clamp (A).
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 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 GTS to the DLC3.
  2. Turn the engine switch on (IG) and turn the GTS 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 tube sub-assembly from the fuel pipe. 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 engine switch off.
4. Disconnect the GTS from the DLC3.