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EG22W±02
9. INSTALL CAMSHAFT OIL SEALS
(a) Apply MP grease to a new oil seal lip.
(b) Using SST and a hammer, tap in the 2 oil sealsSST 09223±46011
10. INSTALL SEMI±CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi±circular plug grooves.
Seal packing: Part No. 08826±00080 or equivalent
(c) Install the 4 semi±circular plugs to the cylinder heads.
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11. INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder heads as shown in theillustration.
Seal packing:
Part No. 08826±00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 8 bolts. Uniformlytighten the bolts in several passes. Install the 2 cylinder head
covers.
Torque: 5.9 N Vm (60 kgf Vcm, 52 in. Vlbf)
12. INSTALL ENGINE HANGERS
Install the engine hanger with the 2 bolts. Install the 2 engine
hangers.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
13. INSTALL ENGINE WIRE TO CYLINDER HEADS
(a) Install the engine wire protector to the RH cylinder head with
the 2 bolts.
(b) Install the ground strap to RH cylinder head with the bolt.
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(c) Install the engine wire protector to the LH cylinder head withthe 5 bolts.
14. INSTALL EGR PIPE Install a new gasket and EGR pipe to the RH exhaust man-
ifold with 2 new nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
15. INSTALL OIL DIPSTICK AND GUIDE FOR ENGINE
(a) Install a new O±ring to the dipstick guide.
(b) Apply soapy water to the O±ring.
(c) Push in the dipstick guide end into the guide hole of the No.1
oil pan.
(d) Install the dipstick guide with the bolt.
(e) Install the dipstick.
16. I N S TA L L O I L D I P S T I C K A N D G U I D E F O R TRANSMISSION
17. INSTALL REAR WATER BYPASS JOINT
(a) Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(b) Install the water bypass pipe to the LH rear engine hanger
with the bolt.
18. INSTALL FRONT WATER BYPASS JOINT
(a) Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
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(b) Install the engine wire protector with the bolt.
(c) Connect the following connectors:(1) ECT sensor connector
(2) ECT sender gauge connector
19. INSTALL INTAKE MANIFOLD
(a) Place 2 new gaskets on the cylinder heads with white painted
mark facing upward.
NOTICE: Align the port holes of the gasket and cylinder head.
Be careful of the installation direction.
(b) Place the intake manifold on the cylinder heads with the
arrow mark facing forward.
NOTICE: Be careful of the installation direction.
(c) Install and uniformly tighten the 6 bolts and 4 nuts in severalpasses.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolt 30 mm (1.18 in.) in length.
20. INSTALL INJECTORS AND DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to a new O±ring, and install it to the injector.
(c) While turning the injector clockwise and counterclockwise, push it to the delivery pipe. Install the 8 injectors.
(d) Position the injector connector outward.
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(e) Place 8 new insulators and the 4 spacers in position on theintake manifold.
(f) Place the 8 injectors and 2 delivery pipes assembly in position on the intake manifold.
(g) Temporarily install the connector bracket and 4 nuts.
(h) Check that the injectors rotate smoothly.
HINT: If injectors do not rotate smoothly, the probable cause
is incorrect installation of O±rings. Replace the O±rings.
(i) Position the injector connector upward.
(j) Tighten the 4 nuts holding the delivery pipes to the intake manifold.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
21. INSTALL FUEL RETURN PIPE
(a) Temporarily install the fuel return pipe with the bolt, 2 new
gaskets and union bolt.
(b) Tighten the union bolt holding the return pipe to the fuel pressure regulator.
Torque: 35 N Vm (360 kgf Vcm, 26 ft Vlbf)
(c) Tighten the bolt holding the return pipe to the LH cylinder
head.
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22. INSTALL ENGINE WIRE TO DELIVERY PIPES, REARWATER BYPASS JOINT AND RH CYLINDER HEAD
(a) Connect the 8 injector connector.
(b) Install the 2 engine wire connectors to the connector on the
LH delivery pipe.
(c) Install the engine wire protector to the RH cylinder head with the 2 bolts.
(d) Install the engine wire protector to the rear water bypass joint
with the 2 bolts.
(e) Install the engine wire protector to the delivery pipes with the 4 bolts.
23. INSTALL ENGINE WIRE TO INTAKE MANIFOLD Install the engine wire protector with the 2 bolts.
24. TEMPORARILY INSTALL EGR PIPE TO RH CYLINDER HEAD
Temporarily install the EGR pipe with the bolt.
HINT: Use bolt 25 mm (0.98 in.) in length.
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25. CONNECT FUEL RETURN HOSE TO FUEL RETURN PIPE
26. CONNECT FUEL INLET HOSE TO LH DELIVERY PIPE
(a) Temporarily connect the fuel inlet hose to the delivery pipe with 2 new gaskets and pulsation damper.
(b) Install the bolt holding the fuel inlet hose to the delivery pipe.
(c) Using SST tighten the pulsation damper. SST 09631±22020
Torque:
39 NVm (400 kgf Vcm, 29 ft Vlbf)
33 N Vm (340 kgf Vcm, 24 ft Vlbf) for SST
HINT: Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
27. INSTALL HEATER WATER HOSES Connect the following noses:
(1) Water hose to water bypass pipe
(2) Water hose to rear water bypass joint
28. INSTALL AIR INTAKE CHAMBER
(a) Install the cold start injector, tube and lead wire assembly with
the 3 bolts.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
(b) Place 4 new gaskets on the intake manifold.
HINT: Gaskets can only be used twice before being replaced.
(c) Place the air intake chamber on the intake manifold.
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(d) Install a new gasket to the EGR pipe.
(e) Temporarily connect the EGR pipe to the air intake chamberwith the 2 bolts.
HINT: Use bolt 20 mm (0.79 in.) in length.
(f) Temporarily install the air intake and and following parts with the 4 bolts and 8 nuts:
(1) VSV for fuel pressure control
(2) Except California:VSV for EGR
(3) Transmission throttle cable bracket
(4) DLC1
(g) Uniformly tighten the bolts and nuts several passes.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolt 40 mm (1.57 in.) in length.
(h) Tighten the 2 bolts holding the EGR pipe to the air intake chamber.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(i) Tighten the bolt holding the EGR pipe to the RH cylinder
head.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(j) Connect the cold start injector tube to the RH delivery pipe
with 2 new gaskets and the union bolt.
Torque: 15 N Vm (150 kgf Vcm, 11 ft Vlbf)
(k) Connect the following connectors:
wCold start injector connector
w VSV connector for fuel pressure control
w Except California:
VSV connector for EGR
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