- Clean the sealing surface of the cylinder head.
- Clean the sealing surfaces of the upper and lower manifold halves.
- Clean any excess carbon deposits from the EGR injector.
- Inspect the upper and lower manifolds for the following conditions:
- Install the lower intake manifold gasket.
- Install the lower intake manifold.
- Install the lower intake manifold nuts.
- Connect the fuel pressure connection fitting.
- Install the fuel injectors.
- Connect the fuel pressure regulator to the lower intake manifold.
- Install the fuel injector retainer bracket.
- Install the upper intake manifold gasket.
- Install the EGR injector.
- Install the upper intake manifold
- Install the upper intake manifold bolts.
- Connect the vacuum harness to the upper intake manifold.
- Install the MAP sensor.
- Install the throttle cable support bracket.
| • | Cracks in the manifold |
| • | Broken flanges |
| • | Gasket surface damage |
Tighten
Tighten the lower intake manifold nuts to 33 N·m (24 lb ft)
in sequence.
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 upper intake manifold bolts to 30 N·m (22 lb ft).
