Intake Manifold Installation
Special Tools
- EN-45059 Angle Meter
- EN-50790 HP Fuel Pump Installation Alignment Gauge
For equivalent regional tools, refer to Special Tools .
Install a NEW gasket (1) on the intake manifold (2). Install the intake manifold and hand start the intake manifold bolts (3, 4).
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CAUTION:
Refer to Fastener Caution .
Tighten the bolts and nuts in sequence twice to 12 N.m (106 lb in).
Install the MAP sensor (2) and bolt (1). Tighten the bolt to 5 N.m (44 lb in).
- NOTE:
The camshaft must be in the base circle position before the high pressure fuel pump is installed.
Use the EN-50790 alignment gauge (2) to ensure that the camshaft lobe is in the base circle position. At base circle position, the tool will be flush with the head (1).
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Lubricate the high pressure fuel pump cylinder head bore with 5W30 engine oil.
- Lubricate the high pressure fuel pump roller lifter (1) with 5W30 engine oil and install into the cylinder head bore.
- Lubricate the NEW O-ring (2) with one drop of clean engine oil. Install the NEW fuel pump housing O-ring (2).
- Install a NEW fuel pump housing gasket (3).
- Install the fuel pump assembly (4).
- Apply theadlocker to the bolts, refer to Adhesives, Fluids, Lubricants, and Sealers .
- Hand start the NEW fuel pump assembly bolts (5) evenly. Tighten the fuel pump bolts evenly to 8 N.m (71 lb in) plus 50 degrees using the EN-45059 meter.
- Hand start both ends of the NEW fuel feed intermediate pipe (7).
- Tighten the fitting nut to the fuel rail to 15 N.m (11 lb ft).
- Tighten the fitting nut to the fuel pump to 15 N.m (11 lb ft).
- Tighten the fitting nut to the fuel rail a final pass to 30 N.m (22 lb ft).
- Tighten the fitting nut to the fuel pump a final pass to 30 N.m (22 lb ft).
- Install the fuel pump insulator (6).
Hand start the fitting nut on the fuel feed pipe (4). Tighten the fitting nut to 30 N.m (22 lb ft).
- Install the fuel feed pipe stud (3).
- Install the fuel pump cover (2) and bolts (1). Tighten the bolts to 10 N.m (89 lb in).
Connect the hose on the radiator inlet pipe assembly (2) to the water outlet assembly.
- Install the radiator inlet pipe bolt (1).
Install a new throttle body gasket (2).
- Install the throttle body (1).
- Install the throttle body bolts (3) and tighten to 10 N.m (89 lb in).
Install the EVAP canister valve tube assembly (2).
- Install the EVAP canister valve (1) and connect the EVAP canister valve tube.
Install the upper intake manifold bracket (2) and bolts (3).
- Install the intake manifold cover (4) onto the camshaft cover.
- Install the intake manifold cover bolt (5) and tighten to 9 N.m (80 lb in).
- Install the oil fill cap (6).
- Install the fuel pump insulator (1).
Ensure that the high pressure fuel pump roller lifter is oriented properly, and the camshaft is at base circle.
Ensure the fuel pump housing gasket (3) is properly aligned with the tab upward at the 2 O'clock position.
Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Ensure the quick-connect is clean and free of debris. The latch should move freely prior to installation.
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.