Intake Manifold Installation

1. Clean any debris from the cylinder head or intake manifold gaskets. Place the intake manifold in position on the cylinder heads.

IMPORTANT: The intake manifold carrier gaskets are attached to the intake manifold through a snap-lock feature. When you install the intake manifold, the carrier gaskets will remain attached to the manifold. It is not necessary to replace the gaskets unless there is damage to the seals.

2. Install the six bolts (3), four studs (1) and spacers (2).
^ Tighten the intake manifold bolts and studs starting from the center and working outward in a circular pattern to 10 Nm (89 in. lbs.).






3. Connect the throttle body coolant hose (3) to the water crossover (4).






4. Connect the fuel rail ground wire at the rear cylinder head.
^ Tighten the fuel rail ground wire retaining bolt to 11 Nm (97 in. lbs.).





5. Install the fuel rail bracket (1) retaining bolt (2) at the rear lift bracket (4).
^ Tighten the fuel rail bracket retaining bolt to 4 Nm (35 in. lbs.).






6. Install the purge solenoid harness and retaining bolt. Connect the hose to the intake manifold.
^ Tighten the purge solenoid harness retaining bolt to 12 Nm (106 in. lbs.).





7. Connect the throttle body coolant outlet hose (1) to the throttle body (3) and place the coolant overflow pipe (5) retaining tabs on the intake manifold studs (4).





8. Place the generator coolant inlet hose (1) and pipe (2) on the intake manifold studs.





9. Connect the PCV dirty air feed tube (1) to the PCV valve and the camshaft cover.






10. Connect the PCV fresh air feed tube (1) to the intake manifold and camshaft cover.





11. Connect the EGR pipe to the throttle body spacer and the water crossover.
^ Tighten the EGR pipe to throttle body spacer bolt to 28 Nm (21 ft. lbs.).
^ Tighten the EGR pipe to water crossover bolt to 28 Nm (21 ft. lbs.).