INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL PORT FUEL INJECTOR ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing a port fuel injector assembly.

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(a) Apply a light coat of spindle oil or gasoline to 4 new O-rings, and install 1 to each port fuel injector assembly.

NOTICE:

Check that there is no damage or foreign matter on the groove of the port fuel injector assembly when installing the O-ring to each port fuel injector assembly.

(b) Install the 4 port fuel injector assemblies to the fuel delivery pipe with sensor sub-assembly. NOTICE: Make sure that the port fuel injector assembly is located within the stopper as shown in the illustration. Check that the port fuel injector assembly installation holes of the fuel delivery pipe with sensor sub-assembly are not damaged and are free of foreign matter. Make sure that the O-ring is not damaged, twisted or moved out of place when installing the port fuel injector assembly.

*a Stopper *b Claw

2. INSTALL NO. 5 ENGINE WIRE

(a) Engage the 2 clamps to install the No. 5 engine wire to the fuel delivery pipe with sensor sub-assembly.

(b) Connect the 4 port fuel injector assembly connectors and fuel pressure sensor connector.

3. INSTALL INJECTOR VIBRATION INSULATOR

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

4. INSTALL NO. 1 DELIVERY PIPE SPACER

(a) Install the 2 No. 1 delivery pipe spacers to the cylinder head sub-assembly.

5. INSTALL FUEL DELIVERY PIPE WITH SENSOR SUB-ASSEMBLY

(a) Place the fuel delivery pipe with sensor sub-assembly with the 4 port fuel injector assemblies onto the cylinder head sub-assembly.

NOTICE:

Be careful not to drop the port fuel injector assemblies when installing the fuel delivery pipe with sensor sub-assembly.

(b) Install the fuel delivery pipe with sensor sub-assembly with the port fuel injector assemblies with the 2 bolts.

Torque:

28.5 N·m {291 kgf·cm, 21 ft·lbf}

6. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly to the fuel delivery pipe with sensor sub-assembly.

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(b) Install the fuel pipe clamp to the fuel tube connector.

7. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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8. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

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9. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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10. INSTALL INTAKE MANIFOLD

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11. INSTALL EGR VALVE ASSEMBLY

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12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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13. INSPECT FOR FUEL LEAK

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14. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing a port fuel injector assembly.

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