Part 2

Intake Manifold





Crankcase Ventilation Tube, Heater Coolant Hose and Upper Radiator Coolant Hose









Generator Support Bracket and Transmission Fluid Filler Tube Support Bracket Bolt









Electrical Connectors, Vacuum Tube and Evaporative Emission (EVAP) Purge Valve Tube Quick Connect Coupling









EGR System Module-To-Exhaust Manifold Tube, EGR System Module and Throttle Body (TB)









Thermostat Housing, Thermostat, Intake Manifold and Gaskets










Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover. Follow the directions on the packaging.

2. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Install the intake manifold in the following sequence.

1. Position the new intake manifold gaskets.

2. Position the intake manifold.

3. Loosely install the 9 intake manifold bolts.

3. Tighten the 9 intake manifold bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





4. Install the thermostat, a new thermostat housing O-ring seal, the thermostat housing and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).

5. Connect the upper radiator coolant hose.

6. Connect the KS electrical connector, electrical connector retainer and the 2 engine wiring harness retainers to the rear of the intake manifold.





7. Connect the 8 fuel injector electrical connectors.

8. Connect the heater coolant hose.

9. Position the generator support bracket and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).

10. Install the 8 ignition coils. For additional information, refer to Ignition System.

11. NOTE: The EGR valve sealing surfaces are soft metals.

Carefully clean both sealing surfaces and install a new EGR system module gasket with the side with the raised ring facing the intake manifold.





12. Install the EGR system module and the 2 bolts.
- Tighten the 2 bolts in 2 stages.
- Stage 1: Tighten to 25 Nm (18 lb-ft).

- Stage 2: Tighten an additional 90 degrees.

13. Position the exhaust manifold-to-EGR system module tube and connect the upper and lower fittings.
- Tighten to 42 Nm (31 lb-ft).

14. Position the vacuum tube assembly and connect the EGR system module vacuum connector.

15. Connect the EGR system module electrical connector.

16. Connect the brake booster vacuum hose to the intake manifold.

17. Connect the electrical connector and the EVAP canister-to-EVAP canister purge valve tube quick connect coupling to the EVAP purge valve. For additional information, refer to Fuel Delivery and Air Induction.

18. Using a new TB gasket, position the TB and install the 4 bolts in 2 stages.
- Stage 1: Tighten to 9 Nm (80 lb-in).

- Stage 2: Tighten an additional 90 degrees (one-fourth turn).

19. Connect the ETC electrical connector and the wiring harness retainer.

20. If equipped, connect the auxiliary heater hose quick connect couplings. For additional information, refer to Heating and Air Conditioning.





21. Position the transmission fluid filler tube and install the transmission fluid filler tube rear bolt.
- Tighten to 28 Nm (21 lb-ft).





22. Install the front transmission fluid filler tube support bracket bolt.
- To install, tighten to 10 Nm (89 lb-in).

23. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction.

24. Connect the fuel supply tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.

25. Install the engine cover.

26. Install the ACL assembly and the ACL outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.

27. Connect the battery ground cable. For additional information, refer to Battery.

28. Fill and bleed the engine cooling system. For additional information, refer to Cooling System &/or Engine Block Heater.