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.
Notice: Refer to Fastener Notice in Service Precautions.
2. Install the six bolts and four studs.
^ Tighten the intake manifold bolts and studs starting from the center and working outward in a circular pattern to 10 Nm (89 inch lbs.).
Important: The following steps are only necessary if the throttle body or intake manifold required replacement.
3. Make sure all mating surfaces for the throttle body spacer and throttle body are clean. Any debris or flawed sealing surfaces could cause vacuum leaks and hinder engine performance.
4. Install the throttle body spacer (1) retaining bolts (2) and throttle body spacer to the intake manifold.
^ Tighten the throttle body spacer bolts (2) to 12 Nm (106 inch lbs.).
5. Install a new throttle body gasket (1) on the throttle body. Make sure all the old gasket material has been removed.
6. Install the four throttle body retaining bolts.
^ Tighten the upper throttle body retaining bolts to 12 Nm (106 inch lbs.).
^ Tighten the lower throttle body retaining bolts to 10 Nm (89 inch lbs.).
7. Press the MAP sensor in position at the top of the spacer mounting location.
8. Align the fuel rail snap lock retainers and fuel injectors in position on the intake manifold.
9. Snap the entire fuel rail and injector assembly into the intake manifold by pressing the fuel rail and injector simultaneously into correct position.
DO NOT force the injector into position or damage to the O-ring seals could occur.
10. Connect the fuel regulator vacuum tube.
11. Install the brake booster vacuum hose.
12. Connect the throttle body coolant hose to the water crossover.
13. Connect the fuel rail ground wire at the rear cylinder head.
^ Tighten the fuel rail ground wire retaining bolt to 11 Nm (97 inch lbs.).
14. Install the quick connect fittings to the fuel rail.
14.1. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet tubes.
14.2. Push both sides of the fitting together in order to snap the retaining tabs/fingers into place.
14.3. Once installed, pull on both sides of the fitting to make sure the connection is secure.
15. Install the fuel rail bracket retaining bolt at the rear left lift bracket.
^ Tighten the fuel rail bracket retaining bolt to 4 Nm (35 inch lbs.).
16. 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 inch lbs.).
17. Connect the throttle body coolant outlet hose to the throttle body and place the coolant overflow pipe retaining tabs on the intake manifold studs.
18. Connect the generator coolant inlet hose to the heater outlet pipe and place the retaining tabs on the intake manifold studs.
19. Connect the PCV valve and both feed tubes to the camshaft covers.
20. Connect the EGR and crankcase ventilation pipe at the throttle body spacer.
21. Route the left bank spark plug wires as shown to prevent wire damage.
22. The left bank wires must be secured in the retaining features formed into the intake manifold.
23. Install the accelerator cable and cruise control cable at the throttle body.
24. Install the TIP sensor and IAC valve connectors.
25. Install the transaxle vent hose and the transaxle shift cable at the bracket.
26. Install the air intake duct.
27. Connect the negative battery cable.
28. To clean, turn the ignition switch to the ON position for two seconds, then turn to the OFF position for ten seconds. Again turn to the ON position and check for fuel leaks.
29. Install the four intake manifold sight shield nuts.
^ Tighten the nuts to 3 Nm (27 inch lbs.).