Intake Manifold: Installation

1. 1.
   
   Install new intake manifold, coolant crossover and thermostat housing gaskets.

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NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.
NOTE: Make sure the fuel rail wiring harnesses are routed correct.
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.
1. 2.
   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.

1. 3.
   
   Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt and install the coolant tube.
   • Tighten to 10 Nm (89 lb-in).

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1. 4.
   
   Connect the upper radiator hose to the intake manifold coolant tube.
   • Install the ground wire and bolt to the engine front cover.
     • Tighten to 10 Nm (89 lb-in).

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1. 5.
   
   Connect the lower radiator hose to the thermostat housing.

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1. 6.
   
   Connect the 2 turbocharger coolant hoses to the intake manifold.

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1. 7.
   
   Connect the 2 heater hoses to the intake manifold.

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1. 8.
   
   Attach the 2 wire harness retainers to the LH valve cover.

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1. 9.
   
   Attach the 2 wire harness retainers to the LH valve cover stud bolt.

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1. 10.
   
   Connect the Manifold Absolute Pressure (MAP) /Intake Air Temperature 2 (IAT2) sensor electrical connector.
   • Connect and attach the 2 fuel injector wiring harness electrical connectors and the 2 wiring harness retainers.

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1. 11.
   
   Connect the PCV tube quick connect coupling to the intake manifold. REFER to Fuel System General Information .

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1. 12.
   
   Attach the EVAP purge valve to the intake manifold.

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1. 13.
   
   Connect the brake booster vacuum hose and EVAP tube quick connect couplings to the intake manifold. REFER to Fuel System General Information .

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1. 14.
   
   Connect the TP sensor and electronic TB electrical connectors.

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NOTE: Align the index marks for the CAC outlet pipe.
1. 15.
   Position the CAC outlet pipe and tighten the clamp.
   • Tighten to 5 Nm (44 lb-in).
   • Connect the TCBP /CAC electrical connector.

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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.
1. 16.
   Install the RH Charge Air Cooler (CAC) tube and turbocharger intake tube as an assembly and install the RH CAC tube nut to the intake manifold.
   • Tighten to 6 Nm (53 lb-in).

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NOTE: Align the index marks for the RH CAC tube.
1. 17.
   Install the RH CAC tube to the RH turbocharger and tighten the clamp.
   • Tighten to 5 Nm (44 lb-in).

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1. 18.
   
   Install the turbocharger bypass valve hose and connect the RH turbocharger bypass valve electrical connector.

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1. 19.
   
   Install the turbocharger wastegate regulating valve hoses to the RH CAC tube and turbocharger wastegate regulating valve.
   • Connect the turbocharger wastegate regulating valve electrical connector.

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1. 20.
   
   Install the bypass valve hose and connect the LH turbocharger bypass valve electrical connector.

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NOTE: Align the index marks for the CAC tube.
1. 21.
   Position the CAC tube and tighten the clamp.
   • Tighten to 5 Nm (44 lb-in).

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1. 22.
   
   Install the ACL outlet pipe. REFER to Intake Air Distribution and Filtering .

1. 23.
   
   Fill and bleed the cooling system. REFER to Engine Cooling .