Part 2

Intake Manifold







Evaporative Emission (EVAP) Purge Valve, PCV Tube, Fuel Supply Tube Quick Connect Coupling, Transmission Fluid Level Indicator Tube and Electrical Connectors











Generator Support Bracket, Upper Radiator Hose, Heater Coolant Hose and Crankcase Ventilation Tube











Ignition Coils, 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. Using a new O-ring seal, install the thermostat.

4. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.

Loosely install the thermostat housing and the 2 bolts.

5. Tighten the 11 bolts in 2 stages in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 25 Nm (18 lb-ft).





6. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

Install the 8 ignition coils and the 8 bolts.

- Apply a light coat of dielectric compound to the inside of the coil boots prior to installation.

- Tighten to 6 Nm (53 lb-in).

7. Connect the 8 ignition coil electrical connectors.

8. Connect the 8 fuel injector electrical connectors.

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

10. If equipped, connect the auxiliary heater hoses. For additional information, refer to Heating and Air Conditioning.





11. Position the EVAP canister purge valve and install the bolt.
- Tighten to 10 Nm (89 lb-in).

12. 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.

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

14. Install the transmission fluid filler tube front support bracket bolt.
- Tighten to 10 Nm (89 lb-in).

15. Position the generator support bracket and install the 2 bolts and the 2 stud bolts.
- Tighten to 10 Nm (89 lb-in).

16. Connect the generator wiring harness retainer to the generator support bracket stud bolt.





17. Connect the ETC wiring harness retainer to the generator support bracket stud bolt.

18. Connect the heater coolant hose.

19. Connect the upper radiator hose.

20. Install the TB spacer. For additional information, refer to Fuel Delivery and Air Induction.

21. Position the crankcase ventilation tube and connect the quick connect coupling to the LH valve cover. For additional information, refer to Fuel Delivery and Air Induction.

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

23. Install the engine cover.

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

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