Intake Manifold Installation (Lower)

1. Apply sealer at the engine block-to-lower intake manifold mating surface.
Ensure that the bead meets the following conditions:
^ 2.0 - 3.0 mm (0.08 - 0.12 in.) wide
^ 3.0 - 5.0 mm (0.12 - 0.20 in.) thick





2. Install the lower intake manifold.

NOTICE: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.

Lower Intake Manifold Tightening Sequence:

3. Apply sealer to the lower intake manifold bolt threads.
4. Install and tighten the lower intake manifold bolts.
Refer to "Revised Lower Intake Manifold Tightening Procedure and Torque". Revised Lower Intake Manifold Tightening Procedure and Torque





5. Install the heater inlet pipe.
6. Install the heater inlet pipe nut.
Tighten the heater inlet pipe nut to 25 Nm (18 ft. lbs.).

IMPORTANT: Do not press on the fuel pressure regulator valve when installing the fuel injector rail assembly.

7. Install the fuel injector rail assembly.
- Lubricate the fuel injector O-rings.
- Install the injector nozzles into the lower intake manifold injector bores.
- Press on the injector rail using the palms of both hands until the injectors are fully seated.





8. Install the fuel injector rail bolts.
Tighten the fuel injector rail bolts to 10 Nm (89 inch lbs.).





9. Install the fuel feed and return pipe retaining clip.
10. Install the fuel feed and return pipe retaining clip bolt.
Tighten the fuel feed and return pipe retaining clip bolt to 8 Nm (71 inch lbs.).