Installation

Installation





1. Position the thermostat housing. Install the upper intake manifold.





Position the upper intake manifold gasket and the intake manifold. Loosely install the bolts.





2. If necessary, install the fuel injector supply manifold.
^ Position the fuel injection supply manifold.
^ Install the seven bolts.





3. Tighten the bolts in two stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).





4. Connect the cylinder head temperature sensor.





5. Install the LH radio interference capacitor.
6. Connect the fuel lines and the vacuum line to the fuel injection supply manifold.





7. Install the ignition coils.
^ Position the 10 ignition coils.
^ Install the 10 bolts.
8. Install the generator.





9. Connect the water temperature indicator sending unit electrical connector.





10. Connect the five LH fuel injector electrical connectors and five LH ignition coil connectors.





11. If equipped, install the EVR solenoid bracket.
^ Position the bracket.
^ Install the bolts.





12. NOTE: The idle air control valve is shown removed for clarity.

Install the throttle body adapter.
^ Position a new throttle body adapter gasket.
^ Position the throttle body adapter.
^ Install four bolts and tighten in two stages.
^ Stage 1: Tighten to 9 Nm (80 inch lbs.).
^ Stage 2: Tighten an additional 85-95 degrees.





13. NOTE: The EGR valve is shown removed for clarity.

If equipped, connect the EVR solenoid vacuum and electrical connectors.





14. If equipped, connect the EGR valve vacuum line.





15. If equipped, install the EGR valve-to-exhaust manifold tube.
^ Hand-tighten the fittings.
^ Tighten the upper fitting to 40 - 60 Nm (30 - 44 ft. lbs.).
^ Tighten the lower fitting to 40 - 60 Nm (30 - 44 ft. lbs.).





16. If equipped, install the EGR transducer bracket.
^ Position the bracket.
^ Install the bolts.





17. If equipped, connect the vacuum lines.





18. If equipped, connect the EGR transducer and throttle We position sensor electrical connectors.





19. Connect the heater hose.





20. Connect the idle air control motor bypass hose and connector.





21. Connect the five RH fuel injector electrical connectors and five RH ignition coil connectors.





22. Connect the vacuum line.





23. Install the RH radio interference capacitor.
^ Position the capacitor.
^ Install the bolt.





24. Connect the vacuum lines to the:
^ brake booster.
^ engine control sensor wiring harness.





25. Connect the PCV vacuum and coolant hoses.





26. Install the accelerator bracket.
^ Position the bracket.
^ Install the bolts.





27. Connect the accelerator and speed control cables and return spring.





28. Install the accelerator cable splash shield.
29. Install the air cleaner outlet tube.





30. Connect the engine water outlet hose and position the hose clamp.
31. Fill the cooling system.
32. Connect the battery ground cable.