- Install the intake manifold.
- Connect the throttle body heater hose to the water crossover feed tube (1).
- Install the hose clamp.
- Install the intake manifold bolts.
- Install the throttle body heater hose insulator (2) to the throttle body heater hose (1).
- Inspect the fuel injector O-rings (2) for misalignment or damage. Replace the O-rings if necessary.
- Install the fuel rail (1) and fuel injectors (2) by aligning the fuel injectors with their respective ports and pressing the four fuel rail snap-lock connectors into the intake manifold until they lock in place. DO NOT apply excessive pressure to the fuel rail in place. The need for excessive pressure may be caused by misalignment of a fuel injector and could cause damage to the seal or intake manifold.
- Install the NEW EGR outlet pipe with NEW O-ring seal.
- Install the EGR outlet pipe (3) to intake manifold bolt (1).
- Install the EGR outlet pipe (3) to water crossover bolt (2).
- Install the PCV valve and connect both feed tubes (1, 2) to the camshaft covers and intake manifold.
- Connect the fuel pressure regulator vacuum tube (1) to the regulator (2) and the throttle body (3).
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.
Important: Tighten the intake manifold bolts in circular pattern starting from the center and moving outward.
Tighten
Tighten the intake manifold bolts to 7 N·m (62 lb in).
Important: The EGR valve outlet pipe incorporates a crush seal connection at the water crossover. The EGR valve outlet pipe must be replaced if disconnected from the water crossover.
Tighten
Tighten the EGR outlet pipe to intake manifold bolt to 10 N·m
(89 lb in).
Tighten
Tighten the EGR outlet pipe to water crossover bolt to 24 N·m
(18 lb ft).
