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 six bolts and four studs.
^ Tighten the intake manifold bolts and studs starting from the center and working outward in a circular pattern to 10 Nm (89 inch lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: The following steps are only necessary if the throttle body or intake manifold required replacement.





3. Make sure all mating surfaces for the throttle body spacer (1) and throttle body are clean. Any debris or flawed sealing surfaces could cause vacuum leaks and hinder engine performance.
4. Install the throttle body spacer retaining bolts (2) and throttle body spacer (1) to the intake manifold.
^ Tighten the throttle body spacer bolts to 12 Nm (106 inch lbs.).





5. Install a new throttle body gasket (1) on the throttle body (3). Make sure all the old gasket material is removed.





6. Place the throttle body (4) in position on the throttle body spacer (1) and install the four throttle body retaining bolts (3).
^ Tighten the throttle body retaining bolts to 12 Nm (106 inch lbs.).

7. Press the MAP sensor in position at the top of the spacer mounting location.





8. Align the fuel rail snap lock retainers and fuel injectors in position on the intake manifold.





9. Snap the entire fuel rail and injector assembly into the intake manifold by pressing the fuel rail and injector simultaneously into correct position. DO NOT force the injector into position or damage to the O-ring seals could occur.
10. Note the location of the fuel rail ground wire (1).





11. Connect the fuel regulator vacuum tube.
12. Install the brake booster vacuum hose.





13. Connect the throttle body coolant hose (3) to the throttle body inlet pipe (1) and Water crossover (4) with hose clamps (2).





14. Connect the fuel rail ground wire at the rear cylinder head.
^ Tighten the fuel rail ground wire retaining bolt to 11 Nm (97 inch lbs.).





15. Install the fuel rail bracket retaining bolt (3) at the rear left lift bracket (4).
^ Tighten the fuel rail bracket retaining bolt to 4 Nm (35 inch lbs.).





16. 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 inch lbs.).





17. Connect the throttle body coolant outlet hose (1) to the throttle body coolant pipe (3) with hose clamps (2).
18. Place the coolant overflow pipe (5) on the intake manifold studs (4).





19. Connect the PCV valve (2) and both feed tubes (1) to the camshaft covers and intake manifold.





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