Installation

NOTE: Step numbers below refer to numbers used in the illustrations.

1. Install new O-rings in place on the two pipe connections and install the heat exchanger in place.
2. Install a new gasket in the cover and install the cover in place.
- Tighten the screws in a circular sequence, starting in the middle to: 20 Nm (15 ft. lbs.).
3. Install the two heat exchanger retaining nuts and tighten to: 30 Nm (22 ft. lbs.).





4. Install the oil cooler pipes and tighten to: 30 Nm (22 ft. lbs.).
5. Install the oil filter and tighten to: 15 Nm (11 ft. lbs.).
6. Install the ignition coil bracket and the ignition coil.
- Plug in the camshaft position sensor connector and the oxygen sensor connector.
7. Install the coolant bridge, radiator hose and electric connectors and tighten to: 30 Nm (22 ft. lbs.).
8. Position a new gasket and install the lower section of the intake manifold.
- Tighten the bolts in a circular sequence to: 20 Nm (15 ft. lbs.).
9. Install the centre intake manifold with fuel rail and tighten to: 20 Nm (15 ft. lbs.).





10. Install the fuel lines.
11. Install the intake manifold.
- First install the following:
- The hose to the EVAP canister purge valve.
- The coolant hoses to the throttle body
- The throttle connector
- The Traction Control System (TCS) throttle body connector
- The Idle Air Control (IAC) valve connector
- The hose to the fuel pressure regulator.

NOTE: Make sure that the pressure regulator's vacuum hose is connected to the front nipple on the throttle housing (in front of the butterfly).

- Tighten all bolts at the mating surface.
- Begin with the bolts in the middle and continue alternately towards the ends.
- Tighten to: 20 Nm (15 ft. lbs.).





12. Install the rubber duct for the mass air flow sensor.
- Install the engine covers.
13. Change the engine oil and oil filter.
- Top up with coolant and check the system for leaks.
14. Check all oil and fluid levels and top up as necessary.
- Make sure that the engine bay is clean.
15. Bleed the cooling system as follows:
- Fill the system up to the MAX level.
- Install the pressure cap, start the engine and warm it up (preferably at different rpm) until the radiator fan starts.
- Remove the pressure cap and run the engine at varying rpm until the radiator fan starts three more times.
- Switch off the engine and top up to the MAX level, if necessary.
16. Drive the car on the road and check all functions.