Installation

CAUTION: When cleaning the cylinder head and block mating surfaces, do not use a metal scraper because the surfaces could be cut or ground. Instead, use a wooden or plastic scraper.

1. Remove covering on intake manifold and clean surface.
2. Clean all surfaces of cylinder block and cylinder heads.





NOTE: Be sure that the PCV valve hose is installed into the grommet before installing intake manifold.





3. Carefully install the intake manifold gaskets.





4. Set intake manifold in position on the engine. Install intake manifold bolts and tighten to 1 Nm (10 inch lbs.) torque. Then tighten bolts to 11 Nm (95 inch lbs.) torque in sequence shown.





5. Lubricate the end of the chassis fuel tube with 30 WT oil. Connect fuel supply hose to chassis fuel tube assembly. pull back on the quick connect fitting to ensure complete insertion. Refer to Powertrain Management.
6. Connect Idle Air Control (IAC) electrical and hose connectors.
7. Connect PCV and canister purge hose harness bundle to intake plenum.
8. Connect brake booster hose to intake plenum








9. Connect ignition coils and the two electrical connectors at rear of engine.
10. Install cowl cover. Refer to Body and Frame.
11. Connect the wiring connector to the Throttle Position Sensor (TPS).
12. Install throttle cable.
13. Install air cleaner and throttle body hose assemblies. Connect intake air temperature sensor electrical connector to air cleaner assembly.
14. Connect negative battery cable.
15. With the DRBIII Scan Tool use Auto Shutdown (ASD) Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test, the ASD relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.