Installation

2GR-FE INTAKE: INTAKE MANIFOLD: INSTALLATION

1. INSTALL INTAKE MANIFOLD

NOTICE:
DO NOT apply oil to the bolts listed below:

(a) Set 2 new gaskets on each cylinder head.

NOTICE:
* Align the port holes of the gaskets and cylinder head.
* Make sure that the gaskets are installed in the correct direction.
(b) Set the intake manifold on the cylinder heads.

(c) Install the intake manifold with the 6 bolts and 4 nuts in the order shown in the illustration.

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

2. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH.

(b) Install the bolt [A].

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

(c) Install the 2 nuts [B].

Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

(d) Install the bolt [C].

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

(e) Install the 3 bolts [D].

Torque : 8.3 Nm (84 kgf-cm, 73 in-lbf)

3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Install 6 new insulators to the intake manifold.

(b) Place the fuel delivery pipe which has the 6 fuel injectors installed to it in position on the intake manifold.

NOTICE:
Be careful not to drop the fuel injectors when installing the fuel delivery pipe.

(c) Temporarily install the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

NOTICE:
After installing the fuel injectors, check that they turn smoothly. If not, reinstall the injectors with new O-rings.

(d) Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

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

(e) Connect the 6 fuel injector connectors.

4. CONNECT FUEL MAIN TUBE

(a) Push in the tube connector onto the pipe until the tube connector makes a "click" sound.

NOTICE:
* Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
(b) Install the No. 2 fuel pipe clamp.

5. TEMPORARILY INSTALL NO. 1 SURGE TANK STAY

NOTICE:
DO NOT apply oil to the bolts listed below:

(a) Temporarily install the intake air surge tank assembly with 3 new gaskets on the intake manifold.

NOTICE:
Do not allow the gaskets to slip out of place during installation.

(b) Temporarily install the No. 1 surge tank stay with the 2 bolts.

6. TEMPORARILY INSTALL THROTTLE BODY BRACKET

NOTICE:
DO NOT apply oil to the bolts listed below:

(a) Temporarily install the throttle body bracket with the 2 bolts.

7. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTICE:
DO NOT apply oil to the bolts listed below:

(a) Install the surge tank with the 4 bolts and 2 nuts in the order shown in the illustration.

Nut - Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

Bolt - Torque : 18 Nm (183 kgf-cm, 13 ft-lbf)

HINT
Use a 5 mm hexagon socket wrench to tighten the 4 bolts.

(b) Connect the 2 water by-pass hoses to the throttle with motor body assembly.

(d) Install the clamp and connect the throttle with motor body assembly connector.

(e) Connect the 4 hoses.

HINT
* E: vapor feed hose
* F: union to check valve hose
* G: No. 1 ventilation hose
* H: vacuum hose
8. FULLY TIGHTEN NO. 1 SURGE TANK STAY

NOTICE:
DO NOT apply oil to the bolts listed below:

(a) Fully tighten the 2 bolts in the order shown in the illustration.

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

9. FULLY TIGHTEN THROTTLE BODY BRACKET

NOTICE:
DO NOT apply oil to the bolts listed below:

(a) Fully tighten the 2 bolts in the order shown in the illustration.

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

10. CONNECT ENGINE ROOM MAIN WIRE

(a) Connect the 5 harness clamps.

11. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

12. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

13. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

14. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

15. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

16. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

17. ADD ENGINE COOLANT Service and Repair

18. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection

19. INSPECT FOR FUEL LEAK Testing and Inspection

20. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

21. INSTALL NO. 1 ENGINE UNDER COVER Installation

22. INSTALL ENGINE UNDER COVER ASSEMBLY Installation