Intake Manifold Assemble

LOWER INTAKE MANIFOLD

NOTICE: Refer to Fastener Notice in Service Precautions.





1. Install the coolant outlet housing, thermostat, and bolts.
Tighten the coolant outlet housing bolts to 40 Nm (30 ft. lbs.).

2. Install the coolant temperature sensor.
Tighten the coolant temperature sensor to 20 Nm (15 ft. lbs.).

IMPORTANT: Lubricate the injector O-ring seals with clean engine oil and install onto the spray tip end of each injector.





3. Install the fuel rail assembly in intake manifold.
Tilt the rail assembly to install the injectors.





4. Install the fuel rail bolts and stud.
- Tighten the fuel rail bolts to 10 Nm (89 inch lbs.).
- Tighten the fuel rail stud to 25 Nm (18 ft. lbs.).





5. Install the MAP sensor, retainer, and nut to the lower intake manifold.
Tighten the MAP sensor retainer nut to 25 Nm (18 ft. lbs.).

UPPER INTAKE MANIFOLD





1. Install the throttle body studs, if removed.
Tighten the throttle body studs to 12 Nm (106 inch lbs.).

2. Install the throttle body gasket.





3. Install the throttle body.





4. Install the throttle body nuts.
Tighten the throttle body nuts to 10 Nm (89 inch lbs.).





5. Install the EGR gasket
6. Install the EGR valve.
7. Install the EGR valve bolts.
7.1. Tighten the EGR valve bolts a first pass to 10 Nm (89 inch lbs.).
7.2. Tighten the EGR valve bolts a final pass to 22 Nm (116 ft. lbs.).





8. Install the EVAP purge solenoid valve.
9. Install the EVAP purge solenoid valve bolts.
Tighten the EVAP purge solenoid valve bolts to 12 Nm (106 inch lbs.).





10. Install the secondary air injection check valve bracket, if removed (RPO K19 only).
11. Install the secondary air injection check valve bracket bolt.
Tighten the secondary air injection check valve bracket bolt to 25 Nm (18 ft. lbs.).