Fuel Injector Installation

Install a new O-ring, grommet and insulator to the injector.

NOTICE:

1. Check that there is no damage or foreign material in the groove of the injector when installing the injector's O-ring.
   

1. Apply gasoline to a new O-ring and install it to the injector.
   

Push and rotate the injector 45° clockwise and counterclockwise to install it to the delivery pipe.

Check that the injector rotates smoothly.

NOTICE:

When the injector does not rotate smoothly, the O-ring may be pinched. Remove the injector and install a new O-ring to the injector.

Install the delivery pipe (with injector) to the intake manifold.

With the condition as stated above, rotate the injector 45° clockwise and counterclockwise.

NOTICE:

When the injector does not rotate smoothly, the O-ring may be pinched. Remove the injector and install a new O-ring to the injector.

With the spacer contacting the delivery pipe, install the delivery pipe with the 2 nuts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Install the delivery pipe (with injector) to the intake manifold.

With the condition as stated above, rotate the injector 45° clockwise and counterclockwise.

NOTICE:

When the injector does not rotate smoothly, the O-ring may be pinched. Remove the injector and install a new O-ring to the injector.

With the spacer contacting the delivery pipe, install the delivery pipe with the 2 nuts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Using a wrench, install 4 new gaskets and 2 fuel pulsation dampers to the fuel pipe with the 2 bolts.

Torque:

39 N*m{398 kgf*cm, 29 ft.*lbf}for use without SST33 N*m{337 kgf*cm, 24 ft.*lbf}for use with SST

Set 2 new gaskets on the cylinder head.

HINT:

Make sure the white paint marks are facing upward.

Install the intake manifold to the gasket and cylinder head with the 6 bolts and 4 nuts.

Torque:

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

Connect the 8 injector connectors.

Install the wire protector (LH side) with the 3 bolts.

Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.

Install the engine wire protector (rear side) to the rear water by-pass joint and RH cylinder head with the 2 bolts.

Install the bracket to the manifold with the bolt, as shown in E in the illustration below.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

Connect the connector.

Install the bracket to the manifold with the bolt, as shown in D in the illustration below.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

Install the bracket of the VSV to the manifold with the bolt, as shown in C in the illustration below.

Torque:

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

Connect the vacuum hose to the VSV, as shown in C in the illustration below.

Connect the connector to the VSV, as shown in C in the illustration below.

Install the bracket to the manifold with the bolt, as shown in B in the illustration below.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

Install the bracket to the manifold with the 2 nuts, as shown in A in the illustration below.

Torque:

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

Install a new gasket and the throttle body with the 2 bolts and 2 nuts.

Torque:

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

Connect the 2 water by-pass hoses.

Connect the connector and wire.

Connect the PCV hose.

Install the connector pipe with the bolt and 2 hose clamps.

Torque:

4.0 N*m{41 kgf*cm, 35 ft.*lbf} for hose clamps

5.0 N*m{51 kgf*cm, 44 ft.*lbf} for bolt

Connect the air hose and No. 1 ventilation hose.

Check for fuel leaks (Click here).

Check for engine coolant leaks (Click here).

Install the cover with the 2 nuts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the side cover with the 2 clips and nut.

Install the side cover with the 3 clips.

Install the intake duct seal with the 7 clips.

Perform initialization (Click here).

NOTICE:

Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.