- Clean the sealing surfaces.
- Insert 4 NEW gaskets.
Notice: Refer to Fastener Notice in the Preface section.
- Install the intake manifold and bolts (1).
Tighten
Tighten the 7 bolts to 20 N·m (15 lb ft).
- Insert a NEW gasket.
- Install the throttle valve module and bolts (1).
Tighten
Tighten the 4 bolts to 9 N·m (80 lb in).
- Install the brake servo vacuum line (1) to the intake manifold.
- Connect the quick release fitting.
- Install the wiring harness bracket (1) to the engine transport shackle.
- Install the bolt (2).
Tighten
Tighten the bolt.
- Connect the 2 wiring harness plugs.
• | Vacuum unit change-over valves (1) |
• | Solenoid valve for change-over valves (2) |
- Install the return line, fuel/air mixture preheating (1).
11.1. | Connect the throttle valve module. |
11.3. | Connect the coolant expansion tank. |
11.5. | Install the intake manifold. |
11.6. | Install the 3 brackets. |
- Install the supply line, fuel/air mixture preheating (2).
12.1. | Connect to the thermostat housing. |
12.2. | Connect the quick release fitting. |
12.3. | Install the throttle valve module. |
12.5. | Install the intake manifold. |
12.6. | Connect the 4 brackets. |
- Connect the wiring harness plug (1).
- Install the engine management wiring harness.
14.1. | Connect the 7 wiring harness plugs: |
• | Valve, intake camshaft adjustment |
14.2. | Clip on the 2 wiring harness brackets. |
- Install the engine control module (ECM). Refer to
Engine Control Module Replacement.
- Install the engine vent hose (1).
• | Connect the 2 quick-release fittings. |
• | Clip the wiring harness to the cylinder head. |
- Apply silicone grease, white, to the injector seal rings and install onto the injection valves.
Important: Inspect the installation position to ensure correct fitting.
- Install the injector valves to the fuel rail and attach with the retaining clamps (1).
- Install the fuel rail (2) and 2 bolts (1).
Tighten
Tighten the bolts to 8 N·m (71 lb in).
- Install the fuel supply line (1) to the fuel rail.
• | Connect the quick release fitting. |
- Attach the engine management wiring harness.
21.1. | Connect the following 9 wiring harness plugs: |
- | Intake camshaft actuator |
21.2. | Clip on the 2 wiring harness brackets. |
- Install the engine vent hose (1).
22.1. | Connect the 2 quick-release fittings. |
22.2. | Clip the wiring harness to the cylinder head. |
- Install the fuel supply line (1) to the fuel rail.
23.2. | Connect the quick-release fitting. |
23.3. | Install into the bracket. |
- Connect the tank vent valve to the intake manifold.
• | Connect the line (1) to the intake manifold. |
• | Connect the rubber mounting (3) to the bracket. |
• | Install the wiring harness plug (2). |
- Install the air cleaner housing. Refer to
Air Cleaner Assembly Replacement.
- Install the wiring harness to the intake manifold.
- Install the intake manifold support (2) and the bolts (3).
Tighten
Tighten the 2 bolts to 8 N·m (71 lb in).
• | Connect the wiring harness plug (1) into the bracket. |
• | Connect the catalytic converter control oxygen sensor wiring harness plug. |