Disassembly and Assembly (U5/Low Emissions)

DISASSEMBLY




1. Disconnect engine ground terminal from intake manifold.
2. Remove ignition coil and ignitor assembly.
3. Remove throttle body.
4. Remove EGR valve.




5. Remove PCV pipe.




6. Disconnect pressure regulator vacuum hose from intake manifold.




7. Remove fuel pipe protector LH.




8. Remove fuel pipe protector RH.
9. Disconnect connector (A) from fuel injector.




10. Remove harness band (B) which holds engine harness onto injector pipe.
11. Remove tumble generator valve actuator.
12. Remove purge control solenoid valve.







13. Remove harness bands which hold engine harness onto intake manifold.

14. Remove engine harness from intake manifold.




15. Remove bolt which installs injector pipe on intake manifold as shown in figure.
16. Remove fuel injectors.




17. Loosen the clamp which holds fuel injector pipe RH onto fuel hose, and disconnect the pipe from fuel hose.




18. Loosen the clamp which holds fuel injector pipe LH onto fuel hose, and disconnect the pipe from fuel hose.




19. Remove bolt which installs fuel pipe on intake manifold.
20. Remove bolt which install pressure regulator to intake manifold.




21. Remove intake manifold RH from tumble generator valve assembly.
22. Similarly, remove intake manifold LH.

ASSEMBLY

1. Install intake manifold RH and LH to tumble generator valve assembly.

NOTE: Always use a new gasket.

CAUTION: This work should be done on cylinder head. (Do not use gasket for the mating surface of cylinder head and intake manifold at this time.)

1. Temporarily tighten (a) - (o) in alphabetical order.
2. Tighten (e) - (k) to 5 N.m (0.5 kgf.m, 4 ft.lb).
3. Tighten (a) - (d) and (i) - (o) to 10 N.m (1.0 kgf.m, 7 ft.lb).
4. Tighten (e) - (g) to 25 N.m (2.6 kgf.m, 18 ft.lb).
5. Tighten (h) - (k) to 25 N.m (2.6 kgf.m, 18 ft.lb).




6. Loosen (a) - (d) and (I) - (o) to remove.

2. Tighten bolt which pressure regulator to intake manifold.

Tightening torque: 5.0 N.m (0.51 kgf.m, 3.7 ft.lb)




3. Tighten bolt which installs fuel pipes on intake manifold.










4. Connect fuel injector pipe to fuel hose, and tighten clamp screw.

NOTE: Tighten clamp screw as shown in the Figure below.

5. Install fuel injectors.










6. Tighten bolt which installs injector pipe on intake manifold.







7. Hold engine harness by harness bands.
8. Install purge control solenoid valve.
9. Install tumble generator valve actuator.
10. Connect connector (A) to fuel injector.




11. Secure engine harness on injector pipe by harness band (B).




12. Install fuel pipe protector RH.




13. Install fuel pipe protector LH.




14. Connect pressure regulator vacuum hose to intake manifold.




15. Install PCV pipe.
16. Install EGR valve.
17. Install throttle body to intake manifold.
18. Install ignition coil and ignitor assembly.







19. Install engine ground terminal to intake manifold.