Upper Intake Manifold Installation

1. Remove tape from lower intake manifold, then clean gasket surface.

2. Install supplied intake manifold gasket. Hold gasket in place with a thin film of sealer on the four (4) corners of the gasket.

3. Position upper intake manifold on top of engine. Do not position manifold in installed position.

NOTE:
PCV heat hoses can be connected to either port.





4. Route new PCV heat hoses to the two (2) taps on the heater coolant tubes where the communicator hose was removed. See Figure 16.

5. Using screw clamps from kit, connect PCV heat hoses to heater coolant tube taps. Tighten clamps to 1-4 Nm (9-35 lb/in).





6. Install bolt 3 before positioning upper intake manifold in installed position. Refer to Figure 17 for bolt location.

7. Install upper intake manifold on lower intake manifold.

8. Install remaining intake manifold retaining bolts. See Figure 17 for proper tightening sequence. Tighten bolts to 16-25 Nm (12-18 lb/ft).

9. Install intake manifold cover plate. Tighten screws to 2.6-3.7 Nm (23-33 lb/in).

10. Connect Vapor Management Valve (VMV) signal and purge lines.

11. Clip engine main harness to rear of intake manifold.

12. Connect vacuum tap to the brake booster.

13. Install the PCV valve in its grommet.

14. Connect the fuel pressure regulator vacuum line.

15. Connect the EGR vacuum regulator and the EGR valve vacuum lines.

16. Connect the EGR vacuum regulator and the EGR valve electrical connectors.

17. Connect the Idle Air Control (IAC) sensor and Throttle Position (TP) sensor electrical connectors.

18. Install the coil pack bracket assembly. Tighten nuts to 16-24 Nm (12-18 lb/ft).

19. Clip the alternator wiring harness to the coil pack bracket.

20. Connect the radio suppressor electrical connector.

21. Connect the ignition coil pack electrical connectors.

22. Install the throttle cable bracket. Tighten bolt to 16-24 Nm (141-212 lb/in), tighten nut at throttle body stud bolt to 8-10 Nm (70-89 lb/in), and tighten nut at coil pack bracket welded stud to 8-10 Nm (70-89 lb/in).

23. Clip the throttle and speed control cables to the intake manifold.

24. Clip the throttle cable to the coil pack bracket.

25. Connect the throttle linkage to the throttle body.

26. Install the throttle linkage cover. Tighten screw to 8-12 Nm (71-106 lb/in).

27. Transfer intake air temperature sensor and both end clamps to new clean air inlet tube.

28. Install the new clean air inlet tube.

29. Connect the Intake Air Temperature (IAT) sensor electrical connector.

30. Install new closure hose between oil fill tube and new tap on air cleaner.

31. Using supplied vacuum cap, cover tap on throttle body where old closure hose was installed.

32. Refill the coolant system.

33. Connect the battery negative cable, then remove the memory saver.

34. Start and run the vehicle to purge any air from the cooling system.

35. Check vehicle for proper operation, and check all coolant hoses for leaks.