Part 2

Intake Manifold














Installation

All vehicles

1. NOTE: The locating tabs on the gaskets must be positioned upward and toward the center of the engine, or a leak will occur.

Install the intake manifold gaskets and the new front module O-ring seal.





2. Install the intake manifold, 5 stud bolts and 11 bolts. Tighten in 3 stages, in the sequence shown.
- Stage 1: Loosely install bolts 1-8.

- Stage 2: Tighten bolts 9-16 to 11 Nm (97 lb-in).

- Stage 3: Tighten all bolts to 11 Nm (97 lb-in).





3. Slide the EGR cooler hose forward and rotate the flat to lock.





4. Install the secondary fuel filter assembly and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).





5. NOTE: Install new sealing washers.

Install the RH fuel tube and banjo bolt.

- For Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).

- For copper sealing washers, tighten to 38 Nm (28 lb-ft).





6. Connect the cylinder head-to-fuel filter tube to the fuel filter assembly and install the nut.
- Tighten the nut to 13 Nm (115 lb-in).

- Tighten the fuel tube coupling to 26 Nm (19 lb-ft).





7. NOTE: Install new sealing washers on the banjo bolt.

Reposition and connect the fuel tubes at the fuel filter housing.

- Tighten the cylinder head-to-fuel filter tube to 26 Nm (19 lb-ft).

- Tighten the fuel return tube to 43 Nm (32 lb-ft).

- Tighten the secondary fuel filter banjo bolt.
- For Viton(R) sealing washers, tighten to 28 Nm (21 lb-ft).

- For copper sealing washers, tighten to 35 Nm (26 lb-ft).





8. Install the secondary fuel filter and cover.
- Tighten to 14 Nm (124 lb-in).





9. Connect the engine coolant vent hose.





10. Connect the MAP sensor hose.





11. Position the engine wiring harness and connect the harness retainers.





12. Connect the 8 fuel injector electrical connectors.





13. Remove the plug or cap. Install the IAT2 sensor.
- Tighten to 18 Nm (159 lb-in).





14. Connect the IAT2 sensor electrical connector.





15. Remove the plug or cap and install the ECT sensor.
- Tighten to 18 Nm (159 lb-in).





16. Connect the ECT sensor electrical connector and the pin-type retainer.





17. Connect the EOT sensor electrical connector.





18. Connect the EOP sensor electrical connector.





19. Connect the EGR valve electrical connector.





20. Connect the wiring retainer and the IPR valve electrical connector and position back the heat insulating wrap.





21. NOTE: Install a new O-ring seal and apply clean engine coolant.

Install the heater tube and the 2 bolts.

- Tighten to 13 Nm (115 lb-in).





22. Install the generator, ground wire and the 3 bolts.
- Tighten to 47 Nm (35 lb-ft).





23. Position the transmission fluid indicator and tube, install the retaining nut and connect the pushpin retainer.
- Tighten to 13 Nm (115 lb-in).





24. Install the transmission fluid indicator and tube nut.
- Tighten to 8 Nm (71 lb-in).





25. Connect the generator B+ wire and electrical connector, position back the boot and connect the wiring pushpin.
- Tighten to 8 Nm (71 lb-in).





26. NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the CAC tube to prevent the tube from blowing off.

Position the CAC tube, oil fill tube and bracket and install the 2 nuts.





27. Connect the oil fill tube at the valve cover.





28. Install the 3 bolts for the CAC tube and oil fill tube.





29. Position the conduit and install the 3 bolts.





30. Connect the pushpin. Position back the MAP sensor assembly and install the bolt.





31. Connect the electrical connector pushpin. Position back the ground wire and install the bolt.





Vehicles with single generator

32. Install the accessory drive belt.





Vehicles with dual generator

33. Install the generator with mounting bracket and the 4 bolts.
- Tighten to 47 Nm (35 lb-ft).





34. Connect the generator B+ wire and electrical connector and position the boot.
- Tighten to 8 Nm (71 lb-in).





35. Install the accessory drive belt tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





36. Position the accessory drive belt idler pulley and install the bracket and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





37. Install the accessory drive belt.





38. Install the accessory drive belt tensioner and bolt.
- Tighten to 25 Nm (18 lb-ft).





39. Install the accessory drive belt.





All vehicles

40. Install the cooling fan stator. For additional information, refer to Cooling System &/or Engine Block Heater.

41. Install the turbocharger pedestal and turbocharger. For additional information, refer to Fuel Delivery and Air Induction.

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