Installation

NOTE: Make sure cylinder head and air intake manifold gasket sealing surfaces are clean.

1. Install new intake manifold gasket.
2. Install intake manifold onto attaching studs.
3. Install intake manifold attaching nuts.

Intake Manifold Bolt Tightening Sequence:

4. In sequence, torque the intake manifold attaching nuts. Torque to 30 Nm (22 ft. lbs.).
5. Install power steering pump assembly. See Steering and Suspension.
6. Install accessory drive belt. Make sure belt is properly aligned on the pulleys.
7. Connect the heater hose at intake manifold outlets. Make sure it is firmly seated.

CAUTION: Whenever fuel line connectors are disconnected, lubricate steel line male ends with clean engine oil. holding steel line, firmly press on female coupler until a click is heard, then pull back to confirm engagement. make sure the fuel line connects are fully seated. pinched, kinked or damaged fuel lines must be replaced.

8. Install fuel supply and return lines. Torque fuel line clip bolt to 7 Nm (62 inch lbs.).

NOTE: When the throttle cable is removed, make sure the locking tangs are fully engaged when assembled if disconnected.





9. Connect throttle cable to throttle body, and throttle cable support bracket. Attach the accelerator control cable bracket. Torque to 30 Nm (22 ft. lbs.).

NOTE: Make sure to confirm positive engagement of electrical connectors and vacuum hoses.





10. Install the following electrical harness connectors and vacuum hoses.
a. Electrical connectors:
- Idle Air Control (IAC).
- Throttle Position (TP) Sensor.
- Manifold Absolute Pressure (MAP) Sensor.
- Fuel injectors (4).
- EGR.
b. Vacuum Hoses:
- EVAP Cannister purge solenoid.
11. Install PCV valve hose.
12. Install air inlet tube, connecting fresh air hose at cam cover.
13. Connect negative battery terminal.
14. With engine off and ignition on, pressurize the fuel system and check for fuel leaks.
15. Install cylinder block drain plugs and close radiator drain. Torque to 35 Nm (26 ft. lbs).
16. Fill with coolant. Use only a non-phosphate ethylene glycol-based antifreeze.

NOTE: Vehicle must be level when filling coolant.

17. Prime fuel system.
a. Cycle ignition on for five seconds and then off for 10 seconds.
b. Repeat step 17a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
d. If engine does not start, repeat steps 17a-17c.
18. Start engine and check for leaks.
19. Fill the cooling system surge bottle to the cold full line. Check coolant level after the engine has run for two to three minutes.