- Clean any debris from the cylinder head or intake manifold gaskets. Place the intake manfiold in position on the cylinder heads.
- Install the six bolts (3), four studs (1) and spacers (2).
- Connect the throttle body coolant hose (3) to the water crossover (4).
- Connect the fuel rail ground wire at the rear cylinder head.
- Install the fuel rail bracket (1) retaining bolt (2) at the rear lift bracket (4).
- Install the purge solenoid harness and retaining bolt. Connect the hose to the intake manifold.
- Connect the throttle body coolant outlet hose (1) to the throttle body (3) and place the coolant overflow pipe (5) retaining tabs on the intake manifold studs (4).
- Place the generator coolant inlet hose (1) and pipe (2) on the intake manifold studs.
- Connect the PCV dirty air feed tube (1) to the PCV valve and the camshaft cover.
- Connect the PCV fresh air feed tube (1) to the intake manifold and camshaft cover.
- Connect the EGR pipe to the throttle body spacer and the water crossover.
Important: The intake manifold carrier gaskets are attached to the intake manifold through a snap-lock feature. When you install the intake manifold, the carrier gaskets will remain attached to the manifold. It is not necessary to replace the gaskets unless there is damage to the seals.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten
Tighten the intake manifold bolts and studs starting from the center
and working outward in a circular pattern to 10 N·m (89 lb in).
Tighten
Tighten the fuel rail ground wire retaining bolt to 11 N·m
(97 lb in).
Tighten
Tighten the fuel rail bracket retaining bolt to 4 N·m (35 lb in).
Tighten
Tighten the purge solenoid harness retaining bolt to 12 N·m
(106 lb in).
Tighten
Tighten the EGR pipe to throttle body spacer bolt to 28 N·m
(21 lb ft).
Tighten
Tighten the EGR pipe to water crossover bolt to 28 N·m
(21 lb ft).
