Special Tools

KM-807 Closure Plugs

For equivalent regional tools, refer to Special Tools.

1. Clean the sealing surfaces.
2. Insert 4 NEW gaskets.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the intake manifold and bolts (1). Tighten the 7 bolts to 20 N·m (15 lb ft).



4. Insert a NEW gasket.
5. Install the throttle valve module and bolts (1). Tighten the 4 bolts to 9 N·m (80 lb in).



6. Install the brake servo vacuum line (1) to the intake manifold.
7. Connect the quick release fitting.



8. Install the wiring harness bracket (1) to the engine transport shackle.
9. Install the bolt (2) and tighten.



10. Connect the 2 wiring harness plugs.

•	Vacuum unit change-over valves (1)

•	Solenoid valve for change-over valves (2)




11. Install the return line, fuel/air mixture preheating (1).

11.1.

Connect the throttle valve module.

11.2.

Fasten the clamp.

11.3.

Connect the coolant expansion tank.

11.4.

Fasten the clamp.

11.5.

Install the intake manifold.

11.6.

Install the 3 brackets.

12. Install the supply line, fuel/air mixture preheating (2).

12.1.

Connect to the thermostat housing.

12.2.

Connect the quick release fitting.

12.3.

Install the throttle valve module.

12.4.

Fasten the clamp.

12.5.

Install the intake manifold.

12.6.

Connect the 4 brackets.




13. Connect the wiring harness plug (1).



14. Install the engine management wiring harness.

14.1.

Connect the 7 wiring harness plugs:

•	Air mass flow meter

•	Throttle valve module

•	Valve, intake camshaft adjustment

•	4 injector valves

14.2.

Clip on the 2 wiring harness brackets.

15. Install the engine control module (ECM). Refer to Engine Control Module Replacement.
16. Install the engine vent hose (1).

•	Connect the 2 quick-release fittings.

•	Clip the wiring harness to the cylinder head.




17. Apply silicone grease, white, to the injector seal rings and install onto the injection valves.

Note: Inspect the installation position to ensure correct fitting.

18. Install the injector valves to the fuel rail and attach with the retaining clamps (1).



19. Install the fuel rail (2) and 2 bolts (1). Tighten the bolts to 8 N·m (71 lb in).



20. Install the fuel supply line (1) to the fuel rail.

•	Remove the 2  KM-807 plugs .

•	Connect the quick release fitting.

•	Clip into the bracket.




21. Attach the engine management wiring harness.

21.1.

Connect the following 9 wiring harness plugs:

-	Engine control unit

-	Air mass flow meter

-	Tank vent valve

-	Throttle valve module

-	Intake camshaft actuator

-	4 injector valves

21.2.

Clip on the 2 wiring harness brackets.

22. Install the engine vent hose (1).

22.1.

Connect the 2 quick-release fittings.

22.2.

Clip the wiring harness to the cylinder head.




23. Install the fuel supply line (1) to the fuel rail.

23.1.

Remove KM-807 plugs .

23.2.

Connect the quick-release fitting.

23.3.

Install into the bracket.




24. Connect the tank vent valve to the intake manifold.

•	Connect the line (1) to the intake manifold.

•	Connect the rubber mounting (3) to the bracket.

•	Install the wiring harness plug (2).




25. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
26. Install the wiring harness to the intake manifold.
27. Install the intake manifold support (2) and the bolts (3). Tighten the 2 bolts to 8 N·m (71 lb in).

•	Connect the wiring harness plug (1) into the bracket.

•	Connect the catalytic converter control oxygen sensor wiring harness plug.