Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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.
Inspect the intake manifold gaskets for damage and install new gaskets if necessary.
- Position the intake manifold and fuel rail assembly onto the engine.
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NOTE: Make sure that the wiring harnesses are correctly located before tightening the intake manifold bolts.
- Install the fuel rail bolts and tighten all the bolts finger-tight.
- Tighten the bolts in 4 stages in the sequence shown.
Torque:
Stage 1: Tighten the intake manifold bolts 1 through 12 to: 89 lb.in (10 Nm)
Stage 2: Tighten the intake manifold bolts 1 through 12 an additional: 45 °
Stage 3: Tighten the fuel rail bolts 13 through 16 to: 89 lb.in (10 Nm)°
Stage 4: Tighten the fuel rail bolts 13 through 16 an additional: 90
- Working through the RH fender well, connect the MAP sensor electrical connector.
- Position the RH fender splash shield back.
- Install the RF wheel and tire. Refer to: Wheel and Tire - Vehicles With: Single Rear Wheels . Refer to: Wheel and Tire - Vehicles With: Dual Rear Wheels .
- Connect the RH fuel rail electrical connectors.
- Inspect the gasket for damage and install new gasket if necessary.
- Install the throttle body housing and the bolts.
Torque: 89 lb.in (10 Nm)
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NOTE: Ensure the hose is fully seated.
Connect the vacuum hoses to the valve on the intake manifold. Use the General Equipment: Hose Clamp Remover/Installer
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NOTE: Ensure the hoses is fully seated.
Connect the vacuum hoses to the valve on the intake manifold. Use the General Equipment: Hose Clamp Remover/Installer
- Connect the wiring harness electrical connectors and retainers.
- Position and connect the PCV tube to the intake manifold and attach the retainer.
- Connect the LH fuel rail electrical connectors.
- Connect the wiring harness electrical connectors and retainers.
- Position and connect the EVAP canister vent solenoid tube quick release coupling. Refer to: Quick Release Coupling
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- Connect the fuel supply line-to-fuel rail quick release coupling. Refer to: Quick Release Coupling
.
- Install the ignition coil-on-plugs. Refer to: Ignition Coil-On-Plug .
- Install and connect the brake vacuum tubes and attach the retainer.
- Connect the brake vacuum tubes to the intake manifold.
- Install the generator bracket and the bolts.
Torque:
Stage 1: 177 lb.in (20 Nm)
Stage 2: 45 °
- Install the generator. Refer to: Generator - 6.2L V8 .
- Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.