Part 2

Intake Manifold





PCV Tube, Body Vacuum Tube Connector, Coolant Heated PCV Fitting Coolant Hoses, Throttle Position (TP) and Electronic Throttle Control (ETC) Electrical Connectors









Throttle Body (TB) and Engine Wiring Harness Retainers









Generator Wiring Harness and Support Bracket, Ignition Coil and Fuel Injector Electrical Connectors









Ignition Coils, Thermostat Housing, Thermostat and Intake Manifold









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 silicone gasket remover and metal surface prep. 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.

Position new intake manifold gaskets and the intake manifold, and loosely install the 11 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.

Position the thermostat housing and loosely install the 2 bolts.

5. Tighten the bolts in the sequence shown in 2 stages.
- 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.

Position the 10 ignition coils and install the 10 bolts.

- Apply silicone brake caliper grease and dielectric compound to the inside of the coil boots prior to installation.

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

7. Connect the pushpin retainer to the intake manifold bracket.





8. Position the engine harness and connect the 3 LH engine wiring harness retainers.

9. Position the engine harness and connect the 2 RH engine wiring harness retainers.

10. Position back the transmission fluid level indicator tube and install the nut.
- Tighten to 10 Nm (89 lb-in).





11. Install the transmission fluid indicator and tube support bracket nut.
- Tighten to 28 Nm (21 lb-ft).





12. Connect the 10 ignition coil electrical connectors.

13. Connect the 10 fuel injector electrical connectors.

14. Connect the heater coolant hose.





15. Install a new TB spacer gasket and the TB and TB spacer as an assembly. Tighten the 4 bolts in 2 stages.
- Stage 1: Tighten to 9 Nm (80 lb-in).

- Stage 2: Tighten an additional 90 degrees.

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





17. Connect the brake booster vacuum hose and the EVAP hose quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





18. Connect the 2 coolant heated PCV fitting coolant hoses and the body vacuum tube connector.

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

20. Connect the TP sensor electrical connector and wiring harness retainer.
- Push in the red clip.

21. Connect the ETC electrical connector.
- Push in the red clip.

22. Install the upper radiator hose.





23. Position the generator harness and the generator B+ terminal and install the nut and protective boot.
- Tighten to 8 Nm (71 lb-in).

24. Connect the generator electrical wiring harness retainer and the generator electrical connector.

25. Connect the fuel hose quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





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

27. Install the engine cover.

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

29. Fill the cooling system. For additional information, refer to Cooling System &/or Engine Block Heater.