Installation
INSTALLATIONFig. 10 O-rings In Cylinder Head:
1. Install new O-rings in the cylinder head Fig. 10. The original O-rings must not be reused.
2. Install the intake manifold. Tighten the intake manifold bolts to 15 Nm (11 ft.lbs.) torque.
3. Push the fuel supply tube over the fuel rail nipples until a click is heard. Pull back to ensure the connector is locked in place.
4. Push the fuel return tube over the fuel pressure regulator nipples until a click is heard. Pullback to ensure the connector is locked in place.
Fig. 7 Injector Harness And CCV Vacuum Hose:
5. Connect the CCV vacuum hose Fig. 7.
6. Connect the fuel injector wire harness to the injectors Fig. 7.
7. Connect the air temperature sensor wire connector.
8. Connect the HVAC vacuum reservoir hose to the fitting on the throttle body adapter.
Fig. 3 Vacuum Hoses / TPS Connector / Idle Air Bypass Hose - Early:
Fig. 4 Vacuum Hoses / TPS Connector And Automatic Idle Speed (AIS) Motor Connections:
9. Connect the air idle bypass hose Fig. 3 to the throttle body adapter or automatic idle speed (AIS) motor Fig. 4 to throttle body.
10. Connect the Throttle Position Sensor (TPS) electrical connector Figs. 3 and 4.
Fig. 5 EGR Valve Transducer Vacuum Hose - Early:
Fig. 6 EGR Valve Transducer Vacuum Hose - Early:
11. Connect the vacuum hose to the EGR valve transducer Figs. 5 and 6.
12. Connect the vacuum connector to the throttle body adapter.
13. Connect the EGR tube.
14. Connect the brake vacuum booster hose Figs. 3 and 4.
Fig. 1 Removing / Installing Bonnet And Throttle Controls - Early:
Fig. 2 Removing / Installing Throttle Cables - Late:
15. Connect the accelerator cable Figs. 1 and 2.
16. Connect the cruise control cable Figs. 1 and 2, if equipped.
17. Connect the transmission kick down cable Figs. 1 and 2.
18. Connect the battery negative cable.
19. Connect the throttle body bonnet Fig. 1 or air inlet hose to throttle body.
20. Start the engine and check for vacuum leaks.