Installation

1AR-FE INTAKE / EXHAUST: INTAKE MANIFOLD: INSTALLATION

1. INSTALL ENGINE MOUNTING DAMPER

(a) Install the engine mounting damper to the intake manifold with the 3 bolts.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

2. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the wire harness clamp bracket to the intake manifold with the bolt.

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

3. INSTALL NO. 1 CHECK VALVE

(a) Connect the 2 vacuum hoses to the intake manifold.

(b) Check that the No. 1 check valve is installed as shown in the illustration.





Text in Illustration





(c) Install the vacuum hose to the 2 hose clamps.

4. INSTALL INTAKE MANIFOLD

(a) Close the tumble control valves Intake System.





Text in Illustration





NOTICE:
The valves may be damaged if they are not closed before installing the intake manifold.

(b) Install a new gasket onto the intake manifold.

(c) Temporarily tighten the 6 bolts to the intake manifold.





(d) Tighten the 6 bolts in the order shown in the illustration.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(e) Connect the intake air control valve actuator connector.

(f) Engage the 2 clamps to the intake manifold.

(g) Install the wire harness clamp bracket with the bolt.

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

(h) Install the wire harness clamp bracket with the bolt.





Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

(i) Engage the 3 wire harness clamps.

(j) Connect the fuel vapor feed hose with the clip.

Text in Illustration





HINT
Connect the hose so that the direction of the hose clip is as indicated in the illustration.

(k) Engage the 3 wire harness clamps.

5. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Install 4 new injector vibration insulators to the cylinder head.





Text in Illustration





(b) Install the 2 fuel delivery spacers onto the cylinder head.

HINT
Install the fuel delivery spacer so that the longer protrusion is on the cylinder head side.

(c) Install the fuel delivery pipe together with the 4 fuel injectors to the cylinder head, and then temporarily install the 2 bolts.





NOTICE:
* Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
* After installing the fuel injectors, check that they turn smoothly. If not, reinstall the injectors with new O-rings.

(d) Tighten the 2 bolts to the specified torque.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(e) Connect the 4 fuel injector connectors.

6. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Line up the pipe and connector and push them together until a "click" sound is heard Service Precautions.





Text in Illustration





NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the tube is inserted securely.
* Check that the tube is securely connected by pulling on it.

7. INSTALL EFI FUEL PIPE CLAMP Installation

8. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

(a) Install the No. 1 vacuum switching valve assembly to the intake manifold with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Connect the No. 2 air hose with the clip.





Text in Illustration





HINT
Connect the hose so that the direction of the hose clip is as indicated in the illustration.

(c) Connect the No. 1 vacuum switching valve connector.

9. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 2 wire harness clamp brackets to the intake manifold with the 2 bolts.

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

(b) Engage the wire harness clamp to the wire harness clamp bracket.

(c) Connect the sensor wire connector.

10. CONNECT UNION TO CONNECTOR TUBE HOSE

(a) Connect the union to connector tube hose to the intake manifold with the clip.

11. CONNECT NO. 2 VENTILATION HOSE

(a) Connect the No. 2 ventilation hose with the clip.





Text in Illustration





HINT
Connect the hose so that the direction of the hose clip is as indicated in the illustration.

12. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

(a) Install the vacuum switching valve assembly to the intake manifold with the bolt.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(b) Connect the 2 vacuum hoses to the intake manifold.

(c) Engage the wire harness clamp to the vacuum switching valve assembly.

(d) Connect the vacuum switching valve connector.

13. INSTALL INLET HEATER WATER HOSE A

(a) Connect the inlet heater water hose A with the clip.





Text in Illustration





HINT
Connect the hose so that the direction of the hose clip is as indicated in the illustration.

14. INSTALL OUTLET HEATER WATER HOSE A

(a) Connect the outlet heater water hose A with the clip.





Text in Illustration





HINT
Connect the hose so that the direction of the hose clip is as indicated in the illustration.

15. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY Installation

16. CONNECT NO. 2 WATER BY-PASS HOSE Installation

17. CONNECT WATER BY-PASS HOSE Installation

18. INSTALL AIR CLEANER HOSE

(a) Install the air cleaner hose with the clip.





Text in Illustration





HINT
Connect the hose so that the direction of the hose clip is as indicated in the illustration.

(b) Install the vacuum hose to the 2 hose clamps.

(c) Connect the vacuum hose.

(d) Install the vacuum hose to the hose clamp.

(e) Install the No. 2 vacuum switching valve assembly to the air cleaner hose.

(f) Install the No. 2 fuel vapor feed hose to the hose clamp.

(g) Connect the ventilation hose assembly to the air cleaner hose with the clip.

(h) Connect the No. 1 air hose with the clip.





Text in Illustration





19. INSTALL AIR CLEANER ASSEMBLY

Installation

20. INSPECT FOR FUEL LEAK

Fuel System