80. 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.

2. Install the four studs (1) and spacers (2) and six bolts (3).

Notice: Refer to Fastener Notice in Service Precautions.

- Tighten the intake manifold bolts and studs starting from the center and working outward in a circular pattern to 10 Nm (89 lb in).





3. Connect the throttle body coolant hose (3) to the water crossover (4).





4. Connect the fuel rail ground wire at the rear cylinder head.
- Tighten the fuel rail ground wire retaining bolt to 11 Nm (97 lb in).
5. Install the fuel rail bracket retaining nut onto the inner EGR valve mounting stud.
- Tighten the fuel rail bracket retaining nut to 18 Nm (13 lb ft).





6. 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 lb in).





7. Connect the throttle body coolant outlet hose (1) to the throttle body (2) and place the coolant overflow pipe (5) retaining tabs on the intake manifold studs (4).





8. Install a new PCV valve in the camshaft cover.





9. Connect the PCV fresh air feed tube (1) to the camshaft cover and the intake manifold.





10. Connect the dirty air PCV feed tube (1) to the PCV valve (2) and camshaft cover.





11. Connect the EGR and crankcase ventilation pipe at the throttle body spacer.