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2500cc Models

  1. Install fuel pipe assembly and pressure regulator, etc. to intake manifold.
  2. Tighten bolt which installs fuel pipes on intake manifold.
    1. Tightening torque:  4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
    Fig 1: Tightening Bolts To Fuel Pipes On Intake Manifold
    G02061435
  3. Connect right side fuel hose to injector pipe, and tighten clamp screw.
    Fig 2: Connecting Right Side Fuel Hose To Injector Pipe
    G02061436
  4. Install fuel injector pipe.
    Fig 3: Installing Fuel Injector Pipe
    G02061437
  5. Connect left side fuel hose to injector pipe, and tighten clamp screw.
    Fig 4: Connecting Left Side Fuel Hose To Injector Pipe
    G02061438
  6. Connect air assist hoses.
    Fig 5: Connecting Air Assist Hoses
    G02061439
  7. Install fuel injectors.
    CAUTION: Always use new o-rings.
    Fig 6: Installing Fuel Injectors
    G02061440
    NOTE: Do not forget to install the fuel injector securing clip.
    Fig 7: Installing Fuel Injector Securing Clip
    G02061441
  8. Tighten bolt which installs injector pipe on intake manifold.
    1. Tightening torque:  3.4 N.m (0.35 kgf-m, 2.5 ft-lb)
    Fig 8: Tightening Bolt To Injector Pipe On Intake Manifold
    G02061442
  9. Tighten bolt which install injector pipe on intake manifold.
    1. Tightening torque:  4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
    Fig 9: Tightening Bolt To Injector Pipe On Intake Manifold
    G02061443
  10. Tighten two bolts which install fuel pipes on the left side of intake manifold.
    1. Tightening torque:  4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
    Fig 10: Tightening Bolts To Fuel Pipes On Left Side Of Intake Manifold
    G02061444
  11. Tighten bolt which install injector pipe on intake manifold.
    1. Tightening torque:  4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
    Fig 11: Tightening Bolt To Injector Pipe On Intake Manifold
    G02061445
  12. Install purge control solenoid valve.
    Fig 12: Installing Purge Control Solenoid Valve
    G02061446
  13. Connect hoses to purge control solenoid valve.
    CAUTION: Carefully connect the evaporation hoses.
    Fig 13: Connecting Hoses To Purge Control Solenoid Valve
    G02061447
  14. Install engine harness onto intake manifold.
  15. Connect connectors to fuel injectors and purge control solenoid valve.
  16. Hold engine harness by harness band (*)
    NOTE: Do not use harness band on harnesses where they are supposed to be protected by the fuel pipe protector.
    Fig 14: Installing Engine Harness Onto Intake Manifold (Secure With Harness Bands)
    G02061448
  17. Install fuel pipe protector LH.
    1. Tightening torque:  18.6 N.m (1.9 kgf-m, 13.7 ft-lb)
    Fig 15: Installing Fuel Pipe Protector LH
    G02061449
  18. Connect pressure regulator vacuum hose to intake manifold.
    Fig 16: Connecting Pressure Regulator Vacuum Hose To Intake Manifold
    G02061450
  19. Install air assist injector solenoid valve to bracket.
    1. Tightening torque:  16 N.m (1.6 kgf-m, 11.6 ft-lb)
    Fig 17: Installing Air Assist Injector Solenoid Valve To Bracket
    G02061451
  20. Connect air by-pass hoses to air assist solenoid valve.
    Fig 18: Connecting Air By-Pass Hoses To Air Assist Solenoid Valve
    G02061452
  21. Connect connector to air assist solenoid valve.
  22. Install throttle body to intake manifold.
    CAUTION: Replace gasket with a new one.
    1. Tightening torque:  1.9-22 N.m (1.9-2.2 kgf-m, 13.7-15.9 ft-lb)
    Fig 19: Installing Throttle Body To Intake Manifold
    G02061453
  23. Connect connector to throttle position sensor and idle air control solenoid valve.
    Fig 20: Connecting Connector To Throttle Position Sensor & Idle Air Control Solenoid Valve
    G02061454
  24. Connect air by-pass hose to throttle body.
    Fig 21: Connecting Air By-Pass Hose To Throttle Body
    G02061455
  25. Install intake air temperature and pressure sensor.
    1. Tightening torque:  2.0 N.m (0.2 kgf-m, 1.4 ft-lb)
    Fig 22: Installing Intake Air Temperature & Pressure Sensor
    G02061456
    CAUTION: Replace O-ring with new one.
    Fig 23: Replacing O-Ring
    G02061457
  26. Connect connector to intake air temperature and pressure sensor.
  27. Install ignition coil and ignitor assembly.
    Fig 24: Installing Ignition Coil & Ignitor Assembly
    G02061458
  28. Connect connector to ignition coil and ignitor assembly.
  29. Install engine ground terminal to intake manifold.
    Fig 25: Installing Engine Ground Terminal To Intake Manifold
    G02061459
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