Installation

NOTE: Before installing manifold. Clean all mating surfaces. Replace all seals, with new seals. All intake manifold fasteners and washers are to be discarded and NEW fasteners and washers are to be used.

1. Install intake manifold onto cylinder head and tighten fasteners to 12 Nm (105 inch lbs.) in sequence shown.
2. Install intake manifold to water inlet support fastener tighten to 12 Nm (105 inch lbs.).
3. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 inch lbs.).
4. Connect PCV and brake booster hoses.
5. Inspect quick connect fittings for damage, replace if necessary. Lube tube with clean 30w engine oil, Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
6. Install throttle body. Tighten fastener to 22 Nm (200 inch lbs.). Install transmission to throttle body support bracket and tighten to 11.9 Nm (105 inch lbs.) at the throttle body first. Next tighten the bracket at the transmission.
7. Connect Manifold Absolute Pressure/Intake Air Temperature Sensor (TMAP) wiring connector.
8. Connect knock sensor connector, and wiring at starter. Connect wiring harness to intake manifold tab.
9. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.
10. Connect vacuum hoses to throttle body.
11. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever.
12. Loose assemble the EGR tube onto valve and intake manifold finger tight. Tighten tube fasteners at the EGR valve first to 11 Nm (95 inch lbs.) then, tighten the intake manifold side fasteners to 11 Nm (95 inch lbs.).
13. Install clean air duct to air filter housing. Tighten clamp to 3 Nm (30 inch lbs.).
14. Connect negative battery cable.
15. Install fresh air duct to air cleaner and tighten wing nut.
16. With the Diagnostic Readout Box (DRB) 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.