Installation
1GR-FE INTAKE: INTAKE MANIFOLD: INSTALLATION
1. INSTALL INTAKE MANIFOLD
Set a new gasket on each cylinder head.
NOTICE:
* Align the port holes of the gasket and cylinder head.
* Be careful of the installation direction.
(a) Set the intake manifold on the cylinder heads.
Install and uniformly tighten the 6 bolts and 4 nuts in several passes.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Text in Illustration
HINT
Tighten the inner installation bolts of the intake manifold before tightening the outer bolts.
2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
3. INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket to the intake air surge tank.
Install the intake air surge tank with the 4 bolts and 2 nuts in the order shown in the illustration.
Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)
Text in Illustration
(b) Install the throttle body bracket with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(c) Install the No. 1 surge tank stay with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(d) Attach the wire harness clamp.
(e) Install the No. 2 surge tank stay with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Connect the No. 1 ventilation hose.
(f) Connect the vacuum hose.
(g) Connect the No. 1 fuel feed hose.
Text in Illustration
HINT
Connect the hose so that the direction of the hose clamp is as indicated in the illustration.
Connect the throttle body connector.
(h) Connect the No. 4 water by-pass hose.
(i) Connect the No. 5 water by-pass hose.
HINT
Connect the hose so that the direction of the hose clamp is as indicated in the illustration.
(j) Connect the 2 heater hose clamps.
Text in Illustration
4. INSTALL AIR TUBE ASSEMBLY
for Bank 1 Side:
Align the paint mark with the projection and connect the air tube assembly to the emission control valve set.
Text in Illustration
HINT
Make sure the direction of the hose clamp is as shown in the illustration.
for Bank 2 Side:
Align the paint mark with the projection and connect the air tube assembly to the No. 2 emission control valve set.
Text in Illustration
HINT
Make sure the direction of the hose clamp is as shown in the illustration.
(a) Install the 3 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Install the wire harness clamp bracket with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(c) Attach the 3 wire harness clamps to the intake air surge tank and bracket.
(d) Connect the purge VSV connector.
(e) Connect the air injection system hose to the air tube assembly shown in the illustration.
Text in Illustration
HINT
* Make sure the paint mark of the air injection system hose is facing upward.
* Make sure the direction of the hose clamp is as shown in the illustration.
5. INSTALL AIR CLEANER HOSE ASSEMBLY
Install the air cleaner hose with the 2 clamps.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
Text in Illustration
(a) Connect the vacuum hose and ventilation hose.
HINT
The direction of the hose clamp is indicated in the illustration.
(b) Attach the wire harness clamp.
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
7. ADD ENGINE COOLANT Service and Repair
8. INSPECT FOR COOLANT LEAK Testing and Inspection
9. INSPECT FOR FUEL LEAK Installation
10. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Replacement
11. INSTALL FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY
(a) Install the front cowl top outer panel with the 7 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the washer hose.
12. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY
Installation