101. Intake Manifold Installation

1. Install the intake manifold.





2. Connect the throttle body heater hose to the water crossover feed tube (1).
3. Install the hose clamp.

Notice: Refer to Fastener Notice in Service Precautions.

Important: Tighten the intake manifold bolts in circular pattern starting from the center and moving outward.





4. Install the intake manifold bolts.
Tighten the intake manifold bolts to 7 Nm (62 inch lbs.).





5. Inspect the fuel injector O-rings (2) for misalignment or damage. Replace the O-rings if necessary.
6. Install the fuel rail (1) and fuel injectors (2) by aligning the fuel injectors with their respective ports and pressing the four fuel rail snap-lock connectors into the intake manifold until they lock in place. DO NOT apply excessive pressure to the fuel rail in place. The need for excessive pressure may be caused by misalignment of a fuel injector and could cause damage to the seal or intake manifold.

Important: The EGR valve outlet pipe incorporates a crush seal connection at the water crossover. The EGR valve outlet pipe must be replaced if disconnected from the water crossover.





7. Install the NEW EGR outlet pipe with NEW O-ring seal.
8. Install the EGR outlet pipe to intake manifold bolt.
Tighten the EGR outlet pipe to intake manifold bolt to 10 Nm (89 inch lbs.).
9. Install the EGR outlet pipe to water crossover bolts.
Tighten the EGR outlet pipe to water crossover bolts to 24 Nm (18 ft. lbs.).





10. Install the PCV valve and connect both feed tubes (1, 2) to the camshaft covers and intake manifold.





11. Connect the fuel pressure regulator vacuum tube (1) to the regulator (2) and the throttle body (3).