Installation

1. If the intake manifold was replaced, perform the following steps:
^ Clean the throttle body O-ring sealing surfaces.
^ Clean the intake manifold sealing surfaces.
^ Install the MAP sensor. See Powertrain Management.
^ Install the throttle body. See Powertrain Management.
^ Install the intake manifold carrier gaskets.
^ Install the fuel rail. See Powertrain Management.

CAUTION: When tightening the intake manifold bolts and studs, start at the center of the manifold and work your way outward in a circular pattern. Only tighten the intake manifold bolts when the engine and manifold are cool. Do not tighten the intake manifold bolts and studs with the engine at operating temperature.





2. Install the intake manifold, six bolts and four studs. Tighten the bolts and studs to 10 Nm (89 inch lbs.).
3. Install the injector harness main connector.
4. Install the PCV hose at the intake manifold.
5. Install the fuel rail bracket at the EGR valve. Refer to Fuel Rail Assembly Replacement.
6. Install the quick connect fittings to the fuel rail.
a. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet tubes.
b. Push both sides of the fitting together in order to snap the retaining tabs/fingers into place.
c. Once installed, pull on both sides of the fitting to make sure the connection is secure.
7. Install the fuel rail ground wire at the rear cylinder head.
8. Install the brake booster vacuum hose at the intake manifold vacuum fitting.
9. Install the EGR pipe and crankcase ventilation pipe at the throttle body spacer. Tighten the EGR pipe bolt to 28 Nm (21 ft. lbs.).
10. Install the throttle body coolant hoses at the throttle body and the surge tank pipe.
11. Install the front bank spark plug wires.
12. Install the accelerator cable and cruise control cable at the throttle body. See Powertrain Management.
13. Install the TP sensor and IAC valve connectors. See Powertrain Management.
14. Install the transaxle vent hose and the transaxle shift cable at the bracket.
15. Install the air intake duct.
16. Install the fuel filler cap.
17. Connect the negative battery cable.
18. 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.





19. Install the four intake manifold sight shield nuts. Tighten the nuts to 3 Nm (27 inch lbs.).