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Intake Manifold Installation (LDK, LHU)

Intake Manifold Installation (LDK, LHU)



1. Install a NEW intake manifold gasket (1).


2. Install the intake manifold (2).

3. Refer to Fastener Caution .

Install the intake manifold bolts and nuts (3) finger tight.

4. Tighten the intake manifold bolts and nuts in sequence:


4.1. Tighten the intake manifold bolts to 25 Nm (18 lb ft) .

4.2. Tighten the intake manifold nuts to 22 Nm (16 lb ft) .

5. Install the EVAP purge solenoid valve (4) and bolt (3). Tighten the bolt to 4 Nm (35 lb in) .


6. Install the MAP sensor (2) and bolt (1). Tighten the bolt to 4 Nm (35 lb in) .

7. Install the intake manifold brace (2).


8. Install the intake manifold brace bolt (1) and nut (3) and tighten to 25 Nm (18 lb ft) .

9. Connect the rear knock sensor to the intake manifold brace.

10. Install the throttle body (1).


11. Install the throttle body bolts (2) and tighten to 10 Nm (89 lb in) .

12. Lubricate the high pressure fuel pump fuel feed line connection threads with clean 5W30 engine oil.


13. Install the fuel feed line. (2)

14. Install the fuel feed line bolts.

15. Connect the low pressure fuel line nut (1) and tighten to 30 Nm (22 lb ft) .

16. Tighten the fuel line bolts to 10 Nm (89 lb in) .

17. Install the high pressure fuel pump noise insulator (1).


18. Install the high pressure fuel pump cover (2).

19. Install the HP fuel pump cover bolts and tighten to 10 Nm (89 lb in) .

20. Install the charger AIR bypass valve solenoid (1) with charger AIR bypass tube assemblies.


21. Install the charger (AIR) bypass valve solenoid bolts and tighten to 10 Nm (89 lb in) .

22.
Note

Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location.


Connect the charger AIR bypass tube assemblies and clips from the charger AIR bypass valve solenoid to the turbocharger and vehicle.

23. Install the charger AIR bypass valve tank assembly (1).


24. Tighten the charger AIR bypass valve tanks assembly bolt to 25 Nm (18 lb ft) .

25. Install the charger (AIR) bypass valve tank unit nut (2) and tighten to 25 Nm (18 lb in) .

26.
Note

Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location. The tube with retaining clamp located on the charger AIR bypass valve tank assembly left side connects to the charger AIR bypass valve solenoid. The right side, permanently attached tube connects to the intake manifold.


Connect the appropriate charger AIR bypass tube assembly to the intake manifold.

27. Connect the final charger AIR Bypass tube assembly from the charger AIR bypass valve tank assembly to the charger AIR bypass valve solenoid.