Installation

INSTALLATION

NOTE: Do not reuse intake manifold gaskets. Always install new gaskets.

1. Apply sealant to the intake manifold gasket, cylinder head side.





2. Install the gaskets onto the cylinder head.

CAUTION: Care must be used to apply the correct amount of sealant onto the gaskets. Applying excessive amounts of sealant may prohibit the intake gaskets from sealing properly.





3. Apply a 5 mm (0.197 inch) bead of the RTV to the front of the engine block sealant areas. Extend the RTV bead 13 mm (0.499 inch) up the cylinder head in order to seal and retain the gaskets.





4. Apply a 5 mm (0.197 inch) bead of the RTV to the back of the engine block sealant areas. Extend the RTV bead 13 mm (0.499 inch) up the cylinder head in order to seal and retain the gaskets.





5. Install the lower intake manifold to the engine. Apply sealer to the lower intake manifold bolts.
6. Install the lower intake manifold bolts.

Tightening Sequence:

7. Use the tightening sequence shown in order to tighten the bolts in three steps:
a. Tighten the bolts in the first pass to 3 Nm (27 inch lbs.).
b. Tighten the bolts in the second pass to 12 Nm (106 inch lbs.).
c. Tighten the bolts in the final pass to 15 Nm (11 ft. lbs.).

8. Install oxygen sensor wire support bracket and nut.
^ Tighten nut to 11 Nm (97 inch lbs.).
9. Install EGR inlet tube, clamp, and bolt.
^ Tighten bolt to 25 Nm (18 ft. lbs.).
10. Install the wiring harnesses. Include the following items:
^ The exhaust gas recirculation (EGR) valve
^ The engine coolant temperature sensor
^ The Central (Sequential Fuel Injector)
^ The MAP sensor
^ The mass air flow sensor
^ Distributor spark plug wires
11. Install the air conditioning compressor bolts into the A/C bracket.





12. Install the fuel supply and return lines to the rear of the lower intake manifold.
13. Install the transmission oil level indicator and tube (Automatic transmissions only).





14. Install the throttle linkage and bracket from the upper intake manifold.
15. Install the heater hoses at the lower intake manifold. Refer to Cooling System.
16. Install the upper radiator hose to the thermostat housing.





17. Install the distributor. Refer to Starting and Charging.





18. Install the air cleaner intake duct.
19. Refill the cooling system. Refer to Cooling System.
20. Connect the negative battery cable.