Intake Manifold: Installation
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NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.NOTE: Make sure the fuel rail wiring harnesses are routed correctly.NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.
Using new intake manifold gaskets and coolant crossover and thermostat housing gaskets, install the intake manifold and the 12 bolts. Tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
- Connect the upper radiator hose to the intake manifold.
- Install the ground wire and bolt to the engine front cover.
- Tighten to 10 Nm (89 lb-in).
- Connect the lower radiator hose to the thermostat housing.
- Connect the 2 turbocharger coolant hoses to the intake manifold.
- Connect the 2 coolant heater hoses to the intake manifold.
- Attach the 2 wire harness retainers to the LH valve cover.
- Attach the 2 wire harness retainers to the LH valve cover stud bolt.
- Attach the 2 wire harness-to-intake manifold retainers.
- Connect the turbocharger wastegate regulating valve electrical connector.
- Connect the MAP /IAT2 sensor electrical connector.
- Connect and attach the 2 fuel injector wiring harness electrical connectors.
- Connect the PCV tube quick connect coupling to the intake manifold. For additional information, refer to Fuel System - General Information
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- Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt.
- Tighten to 10 Nm (89 lb-in).
- Attach the EVAP purge valve to the intake manifold.
- Connect the quick connect coupling EVAP tube to the intake manifold. For additional information, refer to Fuel System - General Information
.
- Connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel System - General Information
.
- Connect the TP sensor and electronic TB electrical connectors.
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NOTE: Align the index marks for the CAC outlet pipe.
Position CAC outlet pipe on the TB and tighten the clamp.
- Tighten to 5 Nm (44 lb-in).
- If equipped, install the noise generator. For additional information, refer to Intake Air System Components -- Exploded View in Intake Air Distribution and Filtering .
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NOTE: Align the index marks for the RH CAC tube.
Install the RH CAC tube to the RH turbocharger and tighten the clamp.
- To install, tighten to 5 Nm (44 lb-in).
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NOTE: Align the index marks for the RH CAC tube.
Install the RH CAC tube and tighten the clamp.
- To install, tighten to 5 Nm (44 lb-in).
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NOTE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler(CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.
Install the RH CAC tube and the RH CAC tube nut to the intake manifold.
- Tighten to 6 Nm (53 lb-in).
- Connect the RH turbocharger bypass valve hose to the RH turbocharger intake tube.
- Connect the RH turbocharger bypass valve electrical connector.
- Connect the 3 turbocharger wastegate hoses.
- Connect the LH turbocharger bypass valve to the RH Charge Air Cooler(CAC) tube.
- Connect the LH turbocharger bypass valve electrical connector.
- Install the ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering .
- Fill and bleed the cooling system. For additional information, refer to Engine Cooling .