Installation

Installation Procedures





1. Clean the sealing surfaces of the cylinder head.
2. Clean the sealing surfaces of the upper and lower intake manifold halves.





3. Clean any excess carbon deposits from the EGR valve.
4. Inspect the upper and lower manifolds for the following conditions:
^ Cracks
^ Broken flanges
^ Gasket surface damage.





5. Install the lower intake manifold gasket.





6. Install the lower intake manifold.





7. Install the lower intake manifold nuts.
^ Tighten the lower manifold nuts to 33 Nm (24 ft. lbs.)
8. Connect the spark plug wires to the electronic ignition coil.





9. Connect the fuel pressure connection fitting.





10. Install the fuel injectors. Refer to powertrain management.





11. Connect the fuel pressure regulator to the lower intake manifold.





12. Install the fuel injector bracket.
13. Connect the wiring to the lower intake manifold.





14. Install the upper intake manifold gasket.





15. Install the EGR injector.





16. Install the upper intake manifold.
17. Install the upper intake manifold bolts.





^ Tighten the upper intake manifold bolts in the sequence shown to 30 Nm (22 ft. lbs.)





18. Connect the vacuum hoses to the upper intake manifold.
19. Connect the wiring to the upper intake manifold.
20. Install the EGR valve.





21. Install the Manifold Absolute Pressure (MAP) sensor.





22. Install the throttle cable support bracket.
23. Connect the throttle cable.
24. Connect the throttle cable support linkage.
25. Connect the cruise control cable assembly if the vehicle is equipped with cruise control.
26. Install the air cleaner duct assembly. Refer to powertrain management.
27. Connect the negative battery cable.