Installation

1. Clean sealing surfaces of intake manifold and cylinder heads.

NOTE: If a new intake manifold is being installed, transfer all necessary components onto new intake manifold.

2. Position new intake manifold gaskets on cylinder heads.
3. Position intake manifold on cylinder heads.
4. Install and hand-tighten eight bolts in locations shown.

NOTE: Make sure alignment tabs on intake manifold gasket are aligned with holes in cylinder heads.

5. Install eight ignition coils and tighten the bolts to 4.5-7 Nm (40-61 inch lbs.).
6. Install the fuel injectors and fuel rail; tighten to 8-12 Nm (71-106 inch lbs.).
7. Install fuel rail crash bracket and tighten the bolts to 20-30 Nm (15-22 ft. lbs.).

Installation Sequence - Gasoline Engine:

8. Tighten the nine bolts in the sequence shown to 20-30 Nm (15-22 ft. lbs.).

NOTE: Upper crash bracket bolt is number six intake bolt and should only be hand-tightened.

9. Replace O-ring seal on water hose connection. Position water hose connection and upper radiator hose and install two bolts and tighten to 20-30 Nm (15-22 ft. lbs.).
10. Install new throttle body adapter gasket.
11. Install throttle body adapter. Tighten five retaining bolts to 8-12 Nm (71-106 inch lbs.).
12. Install accelerator cable bracket stud bolt to intake manifold. Tighten stud bolt to 8-12 Nm (71-106 inch lbs.).
13. Connect EGR valve to exhaust manifold tube to EGR valve. Loosely tighten fitting.

NOTE: Hand-tighten EGR-valve-to-exhaust manifold-tube fitting. Final tightening will be done later in procedure.

14. Connect main emission vacuum control connector to fuel pressure regulator and evaporative emission valve.
15. Install EGR valve heat shield bracket. Tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).
16. Connect fuel charging wiring and transmission to bracket at rear of LH cylinder head.
17. Install fuel charging wire retainers on valve cover stud bolts.
18. Connect fuel charging wiring to EGR vacuum regulator bracket, idle air control valve, EGR transducer and throttle position sensor.
19. Connect fuel charging wiring to 42-pin connector and eight-pin transmission harness connector at power brake booster.
20. Connect accelerator cable and speed control actuator cable.
21. Install heater water hoses.
22. Connect vacuum hose to throttle body adapter vacuum port.
23. Install positive crankcase ventilation valve to valve cover.
24. Connect evaporative emission hose to throttle body adaptor vacuum port and canister purge line.
25. Install generator. Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).
26. Install two bolts retaining generator bracket to generator. Tighten bolts to 8-12 Nm (71-106 inch lbs.).
27. Connect fuel charging wiring to generator.
28. Connect generator wiring harness eyelet on generator stud. Tighten retaining nut to 7-9 Nm (62-80 inch lbs.).
29. Connect generator wiring harness to junction box at front fender apron.
30. Connect fuel charging wiring to ignition coils, fuel injectors and camshaft position sensor.
31. Raise vehicle on hoist.
32. Connect fuel charging wiring to heated oxygen sensors, and the radio ignition interference capacitor.
33. Connect EGR valve to exhaust manifold tube to EGR valve tube to manifold connector. Tighten fitting to 35-45 Nm (26-33 ft. lbs.).
34. Connect EGR transducer hoses to EGR valve to exhaust manifold tube.
35. Connect fuel charging wiring to oil pressure sensor, power steering pump and oil filter adapter bracket.
36. Install oil bypass filter.
37. Connect fuel charging wiring to both crankshaft position sensor and A/C clutch.
38. Lower vehicle.
39. Install drive belt.
40. Install EGR valve to exhaust manifold tube to EGR valve. Tighten fitting to 35-45 Nm (26-33 ft. lbs.).
41. Install windshield wiper governor.
42. Connect fuel lines. Install air cleaner outlet tube.
43. Install air cleaner outlet tube.
44. Install the fan motor.
45. Connect battery ground cable.
46. Fill and bleed engine cooling system.
47. Check and fill crankcase to specified level with clean Super Premium SAE 10W30 Motor Oil XO-10W30-QSP.
48. Start engine and check for leaks.