Intake Manifold - Installation

INSTALLATION

NOTE: Before installation, clean cylinder heads and intake manifold surfaces.





1. Properly position the intake manifold gasket and install the intake manifold.

CAUTION: The right intake manifold upper thermostat housing bolts should be tightened to 8.4 Nm (74 in. lbs.).

2. Tighten bolts to 16 Nm (142 in. lbs.), starting in the middle and tightening in a cross pattern outward until reaching the upper thermostat bolts on the right front manifold.
3. Tighten the upper thermostat bolts on the right cylinder head to 8.4 Nm (74 in.lbs.).





4. Install the fuel filter.
5. Position and install the fuel filter supply and return pipe harness.
6. Position and install the fuel injector return fuel hose harness.
7. Position and properly route the engine wiring harness.
8. Install the left fuel rail. Tighten bolts to 27 Nm (20 ft. lbs.).
NOTE: Inspect the fuel lines, especially around the barrel ends for damage. Replace as necessary.
9. Install the fuel rail transfer line along with the right fuel rail. Tighten fuel rail bolts to 27 Nm (20 ft. lbs.), and fuel pipe to 33 Nm (24 ft. lbs.).
10. Install the fuel injector high pressure lines. Tighten lines to 27 Nm (20 ft. lbs.).
11. Connect the swirl valve motor electrical connector.





12. Connect the EGR and EGR temperature sensor wiring harness connectors.
13. Connect the coolant hose at the EGR housing.
14. Install the EGR tube to the EGR housing.
CAUTION: Observe the positioning of the oil housing to block gasket. This gasket must be attached to the housing and both oil passages aligned properly. Failure to do so will result in immediate turbocharger damage upon start up.
15. Install the turbocharger oil housing adaptor.
16. Install the turbocharger.Turbocharger - Installation
17. Install the right rear engine cover bracket and connect the transmission oil level indicator tube.
18. Install the charge air outlet tube.
19. Install the EGR air control valve assembly.
20. Install the glow plug module.





21. Install the air cleaner cover and air inlet tube.
22. Install the engine cover.
23. Install the strut tower support.
24. Fill the engine with coolant.
25. Connect the negative battery cable.

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1350 bar (19,580 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Fuel under this amount of pressure can penetrate skin causing serious or fatal injury.

26. Start the engine, allow to warm, turn the engine off and inspect for leaks.