INTAKE MANIFOLD INSTALLATION

INSTALL INTAKE MANIFOLD
1. Set 2 new intake manifold to head gaskets on each cylinder head.
  Note
  
  Align the port holes of the gaskets and cylinder head.
  
  Make sure that the gaskets are installed in the correct direction.
2. Set the intake manifold on the cylinder head.
3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL FUEL INJECTOR ASSEMBLY
1. Text in Illustration
  
  *1 New O-ring
  
  Apply a light coat of spindle oil or gasoline to new O-rings, and install them to each injector.
2. Apply a light coat of spindle oil or gasoline where the fuel delivery pipe contacts each O-ring.
3. Push and twist each fuel injector to install them into the fuel delivery pipe.
4. Position each fuel injector connector outward.
  Note
  - Be careful not to twist the O-rings.
  - After installing a fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
5. Install 6 new injector vibration insulators to the intake manifold.
6. Place the fuel delivery pipe with the 6 fuel injectors in position on the intake manifold.
  
  Note
  
  Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
7. Temporarily install the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.
  
  Note
  
  After installing the fuel injectors, check that they turn smoothly. If not, reinstall the injectors with new O-rings.
8. Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
9. Connect the 6 fuel injector connectors.

Text in Illustration
*1	New O-ring

CONNECT FUEL TUBE SUB-ASSEMBLY

Text in Illustration
*1	No. 2 Fuel Pipe Clamp
*2	Retainer
*3	Fuel Tube Connector
*4	O-ring
*5	Pipe

Push in the tube connector onto the pipe until the tube connector makes a "click" sound.

Note

Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

Install the No. 2 fuel pipe clamp.

INSTALL NO. 2 ENGINE MOUNTING STAY RH
1. Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.
  
  Torque:
  
  Bolt
  
  38 N*m { 387 kgf*cm, 28 ft.*lbf }
  
  Nut
  
  23 N*m { 234 kgf*cm, 17 ft.*lbf }

INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTICE

DO NOT apply oil to the bolts listed below:

Tightening Part
Surge Tank and Intake Manifold
No. 1 Surge Tank Stay and Surge Tank
Throttle Body Bracket and Surge Tank

Install 3 new air surge tank to intake manifold gaskets to the intake air surge tank.
Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

Torque:

Bolt

18 N*m { 184 kgf*cm, 13 ft.*lbf }

Nut

16 N*m { 163 kgf*cm, 12 ft.*lbf }
Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Connect the connector to the intake air control valve assembly.
Connect the ventilation hose and vacuum hose.
Connect the 2 water by-pass hoses to the throttle body assembly.
Connect the vacuum hose clamp and fuel vapor feed hose.
Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.
Text in Illustration

*1 for RHD:

*2 for LHD:

Connect the union to check valve hose.

INSTALL AIR CLEANER ASSEMBLY
1. Install the air cleaner assembly Click here.
INSPECT FOR FUEL LEAK
1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs Click here.

Text in Illustration
*1	for RHD:
*2	for LHD: