NOTE: Access to one of the intake manifold bolts is
through a supplied hole in the manifold.
(16) Remove th e rema ining int ake manifold bolts,
lift th e intake manifold u p and out while guiding t he
engine wirin g harness and fuel lines thr ough th e
openin gs in the in take man ifold, th en r emove t he
gasket (Fig. 70).
NOTE: Install the EGR valve with new gasket onto
the new intake manifold if the intake manifold is
being replaced.
INSTALLATION
NOTE: If the intake manifold is being replaced,
install the EGR valve with new gasket.
(1) Clean both m ating surfa ces and insta ll a new
intake manifold gasket with the int ake manifold.
Guide the en gine wiring har ness and fuel lines
through t he intake ma nifold openings. Tight en ma n-
ifold bolts t o 16 N·m (142 lbs. in.) in a cross direc-
tional pat tern beginning with th e middle bolts an d
tightenin g outwa rd to t he en ds.
(2) Raise and support the vehicle.
(3) In st all the rear intake manifold bolts an d
tighten to 16 N·m (142 lbs. in.) (F ig. 70).
(4) In st all the lower intake m anifold support
bracket. Tight en bolt s to 20 N·m (177 lbs. in.) (Fig.
70).
(5) Lower th e vehicle.
(6) Connect both fuel lines to fuel filter assembly
(Refer to 14 - FUEL SYSTEM/FUEL DE LIVE RY/
FUE L FILTER - INSTALLATION).
(7) Connect the coolan t hose a t the EGR valve
(Fig. 69).
(8) Secure t he engine wiring harness and cable
du ct to the int ake manifold. tigh ten fasten er to 9N·m
(80 in . lbs.).
(9) Connect the EGR wir ing harness con nector
(Fig. 69).
(10) Connect t he fuel pressur e sensor electrical
connect or
(11) In st all t he fuel r ail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVE RY/FUE L RAIL - INSTALLA-
TION).
NOTE: The high pressure fuel lines must be counter
held when tightening to prevent damage.
(12) Install t he high pressu re fuel lines (Refer t o
14 - FUEL SYSTEM/FUEL DE LIVE RY/FUEL LINES
- INSTALLATION).
(13) Connect t he charge air hose to th e intake
manifold (Fig. 69).
(14) Install the engine cover (Refer to9-ENGINE
- INSTALLATION).
(15) Fill t he cooling system .
(16) Connect t he negat ive batt ery cable.
(17) Star t the en gin e, run until wa rm, tu rn engine
off and inspect for leaks. Care must be ta ken to
observe the fu el system war ning. (Refer t o 14 - FUEL
SYSTEM - WARNING).
EX H AU ST M AN I FOLD
REMOVAL
(1) Disconn ect the n egat ive battery cable.
(2) Remove the exha ust hea t shield.
(3) Raise and support the vehicle.
(4) Remove the turboch arger support bracket .
(5) Loosen the exh aust pipe to en gine bracket fas-
teners at th e rea r of the engine block.
(6) Remove th e exh aust hanger fasteners a t the
muffler.
(7) Disconn ect the front exha ust pipe to tu rbo-
charger fastener (Fig. 71).
Fig. 70 INTAKE MANIFOLD
1 - INTAKE BOLT ACCESS HOLE
2 - INTAKE MANIFOLD
3 - SUPPORT BRACKET
9 - 68 ENGINE VA
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