Intake Manifold - Installation

INSTALLATION





1. If required, install the following components on the intake manifold:
- Throttle body Throttle Body - Installation.
- Fuel rail Fuel Rail - Installation.
- Fuel injector(s) Fuel Injector - Installation.
- Evaporative emissions purge solenoid Evap Purge Solenoid - Installation.
- IAT/MAP sensor Installation.

2. Install four new intake manifold seals (1).






CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

3. Install the intake manifold (1) to the engine through the space normally occupied by the battery. Loosely install an intake manifold flange bolt (3) and the support bolt (2) to hold the intake manifold in position.






NOTE: Automatic transmission equipped engine mount shown, manual transmission equipped engine mount similar.

4. Slowly raise the engine so that the RH engine mount isolator (3) can be reinstalled.
5. Install the RH engine mount isolator (3) and support bracket (1) to the engine mount bracket with three bolts. Tighten the isolator to engine bracket bolts in the sequence shown to 60 Nm (44 ft. lbs.).
6. Install the RH engine mount isolator (3) to the body with three bolts (2). Tighten the isolator to body bolts (2) to 60 Nm (44 ft. lbs.).





7. Connect the lower coolant hose to the radiator.
8. Install the pressurized coolant bottle (5) Coolant Recovery Bottle - Installation.





9. Raise and support the vehicle Maintenance.
10. Install the remaining six of the seven intake manifold flange bolts. Tighten all seven intake manifold flange bolts in the sequence shown to 15 Nm (11 ft. lbs.).





11. Position the wire harness and close the two wire harness retainers (1).





12. If equipped with a manual transmission, install the rear engine mount isolator (7) to the transmission with the rear engine mount bracket bolt (3) and nut (6) tightened to 80 Nm (59 ft. lbs.) and tighten the isolator bolt (1) to 130 Nm (96 ft. lbs.).





13. If equipped with an automatic transmission, install the rear engine mount isolator (5) in the bracket (3) with two bolts (4) tighten to 60 Nm (44 ft. lbs.). Install the isolator bolt (1) and tighten to 130 Nm (96 ft. lbs.).





14. Lower the vehicle.
15. Tighten the previously installed intake manifold support bolt (2) to 8 Nm (90 in. lbs.).





16. Connect the heater core outlet hose (3) and inlet hose (4) to the heater core.





17. Install the A/C compressor (1) A/C Compressor - Installation.





18. Install the accessory drive belt (4) Serpentine Accessory Drive Belt - Installation.





19. Install the frame splash shield (3) with three screws (1).
20. Install two screws (2) to the front wheelhouse splash shield.
21. Install the right vertical brace (5) with two bolts (4) tightened to 45 Nm (33 ft. lbs.).





22. Install the engine cooling fan (2) Cooling Fan - Installation.





23. Raise and support the vehicle Maintenance.
24. Remove four bolts (1) and install the tunnel support brace (2). Reinstall the bolts (1) and tighten to 90 Nm (60 ft. lbs.).





25. Install the belly pan Belly Pan - Installation.





26. Connect the vacuum supply line to the pump (1).





27. Install the oil separator housing bracket (1) with two bolts (2) and one nut (3). Tighten the three fasteners to 13 Nm (115 in. lbs.).





28. Connect the fuel vapor purge hose (3) to the intake manifold.
29. Connect the fuel line (2) to the fuel rail and close the hose retainer (1)Service and Repair.





30. Connect and lock the electrical connector (3) to the Electronic Throttle Control (ETC) (4) and engage the ETC harness to the clip (2) on the throttle body.





31. Connect and lock the fuel injector wire harness connector (2).
32. Connect and lock the evaporative emissions purge solenoid harness connector (1).





33. Connect and lock the IAT/MAP sensor harness connector (3).





34. Install the ground strap (4) to the PCM (2) with nut (1) tightened to 5 Nm (44 in. lbs.).
35. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).





36. Install the battery tray (3) with one nut (5) and two bolts (1). Tighten all three fasteners to 25 Nm (18 ft. lbs.).
37. Engage the engine wire harness connector (2) to the battery tray (3).
38. Engage two engine wire harness retainers (4) to the battery tray (3).
39. Engage two starter wire harness retainers (6) to the battery tray (3).





40. Connect the Powertrain Control Module (PCM) harness connectors (1 and 2).





41. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 Nm (115 in. lbs.).
42. Connect the vent hose (3) to the oil filler neck.
43. Connect the PCV hose (1) to the intake manifold.





44. Install the air cleaner body (6) Air Cleaner Body - Installation.





45. Fill the cooling system Service and Repair.

CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

46. Install and connect the battery Battery - Installation.
47. Evacuate and charge the refrigerant system Refrigerant System Charge.
48. Install the engine cover (1).
49. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair.