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.
Upper Intake Manifold: Installation
Make sure gasket surfaces of upper and lower intake manifold are clean. Place new gasket on lower manifold and mount upper manifold to lower with 5 bolts. Attach electrical connectors to air by-pass valve and throttle position sensor.
- Make sure gasket surfaces of upper and lower manifolds, turbocharger and cast tube are clean. Place new gasket on lower manifold assembly and mount upper intake manifold to lower. Tighten bolts and nuts.
- Install injector wiring harness and engine oil dipstick bracket. Connect EGR tube to EGR valve. Connect PCV system. Connect vacuum connections. Position cast tube gasket on turbocharger. Install retaining bolts and tighten. Install air throttle body/cast tube assembly to fuel charging assembly.
- Install retaining nuts and tighten. Connect accelerator cable. Connect electrical connectors to air by-pass valve and throttle position sensor. Connect negative battery cable and fill cooling system.
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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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.
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