Installation

Installation

1. Install the upper intake manifold gasket.






2. Install the upper intake manifold.
3. Install the water outlet.






4. Install the upper intake manifold bolts. Torque in sequence to:
Torque vertical bolts in sequence to 15 Nm (11 ft. lbs.).
Torque the water outlet bolts in sequence to 27 Nm (20 ft. lbs.).
Torque the side bolts in sequence to 30 Nm (22 ft. lbs.).






5. Use the following procedure to install the fuel rail:
a. Using clean engine oil, lightly lubricate the fuel injector O-rings.
b. Install the injectors of the rail into the bores of the manifold.
c. Carefully press the fuel rail with the palms of both hands until the injectors are fully seated.
6. Install the fuel rail nuts. Torque the fuel rail nuts to 10 Nm (89 inch lbs.).
7. Install the electrical connectors to the fuel injectors.
8. Install the thermostat and thermostat housing. See Cooling System.
9. Install the EGR valve outlet pipe.
10. Install the throttle body to the upper intake manifold, if necessary.
11. Install the air cleaner. Install the air cleaner outlet duct. Install the resonator duct.
12. Connect the wiring harness to the rosebud clips at the fuel rail.
13. Install the electrical connectors at the following locations:
- The idle air control
- The throttle position sensor
- The mass airflow sensor
- The intake air temperature sensor.






14. Install the generator brace to the upper intake manifold.
15. Install the brake booster hose to the upper intake manifold.
16. Install the ignition control module.
17. Install the accelerator control cable bracket to the throttle body. Install the accelerator control cables to the throttle body.
18. Install the accelerator control cable bracket bolts. Torque the bolts to 10 Nm (89 inch lbs.).
19. Install the fuel lines to the fuel rail.
20. Install the IAC valve to the upper intake manifold.
21. Install the fuel pressure regulator and the canister purge harness.






22. Install the MAP sensor.






23. Install the vacuum source to the upper intake manifold.
24. Install the drive belt tensioner.
25. Install the generator. See Starting and Charging.
26 Install the transmission level indicator, if necessary.
27. Install the drive belt.
28. Refill the engine coolant. See Cooling System.
29. Connect the negative battery cable.