Installation

1. Transfer all necessary components to new intake manifold.

2. Clean intake manifold to cylinder head gasket surface.

3. Install new intake manifold gaskets.





4. With an assistant's help, install intake manifold assembly. Tighten screws in sequence shown in Figure 9, to 20-30 Nm (15-22 lb/ft). Hand tighten bolt No. 7 prior to final tightening.

5. Clip fuel charge wiring harness to studs on left side valve cover.

6. Connect Idle Air Control (IAC) motor electrical connector.

7. Connect Throttle Position (TP) sensor electrical connector.

8. Attach two (2) wiring harnesses to clip on left rear of intake manifold.

9. Connect fuel lines to spring clips.

10. Connect fuel charge wiring harness to left side fuel injectors, Engine Coolant Temperature (ECT) sensor and retaining stud.

11. Connect throttle and speed control cables to throttle body.

12. Connect radiator hose to thermostat housing.

13. Install alternator. Tighten bolts to 20-30 Nm (15-22 lb/ft).

14. Position alternator upper support bracket close to installed position, then connect all alternator electrical connectors.

15. Install alternator upper support bracket. Tighten bolts to 8-12 Nm (71-106 lb/in).

16. Attach alternator wiring harness to intake manifold.

17. Install drivebelt on alternator.

18. Connect main engine wiring harness pushpin to rear of intake manifold.

19. Connect two (2) vacuum lines to top of throttle body adapter.

20. Connect vacuum line to EVAP solenoid.

21. Connect EGR tube to EGR valve. Tighten nut to 35-45 Nm (26-33 lb/ft).

22. Clip throttle/speed control cables on routing bracket.

23. Clip fuel charge wiring harness to fuel supply manifold, then connect right side fuel injectors, Engine Coolant Temperature (ECT) sender and EGR Vacuum Regulator (EVR) solenoid.

24. Install PCV valve and hose.

25. If equipped with ignition wires, connect the ignition wires to spark plugs and routing clips. If equipped with a coil-on-plug system, install and connect individual coils to each cylinder.

26. Install air cleaner outlet tube.

27. Connect battery negative cable, then remove memory saver.

28. Fill cooling system as follows:

^ Fill coolant recovery reservoir with 50/50 mixture of antifreeze and water until the mixture flows out of the disconnected heater hose.

^ Connect heater hose to right rear corner of intake manifold.

^ Fill coolant recovery reservoir to below the filler neck seat.

^ Place heater temperature selector in Maximum heat position.

^ Install pressure relief cap.

^ Start and run engine until normal operating temperature (thermostat opens) is reached.

^ Stop engine and allow to cool.

^ Refill reservoir to the COLD FULL LEVEL.

29. Check engine for fuel and cooling system leaks.