Fuel Charging Assembly: Installation
- Clean and inspect mounting faces of the fuel charging manifold assembly and cylinder head. Surfaces must be clean and flat. Clean and lubricate manifold stud threads. Install new gasket. Position the lower manifold assembly to head and install engine lifting bracket.
- Install 4 upper manifold retaining nuts fingertight. Install 4 remaining manifold nuts and tighten all nuts in sequence. See Fig 1 and Fig 2 . Install the fuel supply manifold with 2 retaining nuts. Tighten bolts. Connect 4 electrical connectors to injectors. Make sure gasket surfaces are clean.
- Place a new gasket on lower intake manifold assembly and place the upper intake manifold in position. Install retaining bolts and tighten. Install engine oil dipstick and injector wiring harness bracket. Tighten retaining bolts or nuts. Connect fuel supply and return lines. Connect EGR tube to upper intake manifold and tighten.
- Connect water by-pass line. Connect the PCV system hose to the fitting on the underside of the upper intake manifold. Connect upper intake manifold vacuum connections, including rear vacuum line from dash panel to vacuum tee, EGR valve and fuel pressure regulator. Hold accelerator cable bracket in position on upper manifold and install retaining bolt.
- Tighten bolt. Install accelerator cable top bracket. Position cast tube gasket on turbocharger. Be sure surfaces of cast tube and turbocharger are clean. Position new gasket on fuel charging assembly and throttle body mounting flange.
- Install cast tube/air throttle body assembly on the turbocharger. Make sure gasket is in correct position. Install 2 cast tube retaining bolts and tighten. Install air throttle body/cast tube assembly to fuel charging assembly. Install 4 retaining nuts. Connect accelerator cable.
- Connect electrical connectors to air by-pass valve, throttle position sensor, injector wiring harness, knock sensor, fan temperature sensor and coolant temperature sensor. Connect battery ground. Refill cooling system.
- Clean and inspect the mounting faces of the fuel charging manifold assembly and cylinder head. Surface must be clean and flat. Clean and lubricate manifold stud threads. Install new gasket. Install manifold assembly to head and tighten top middle nut fingertight.
- Install fuel return line in the fuel supply manifold. Install 2 manifold mounting nuts fingertight. Install dipstick in block and secure with bracket fingertight. Install remaining 3 manifold mounting nuts and tighten all nuts. Install EGR tube with 2 oil coated flange nuts.
- Mount separator bracket to head. Install hose on rocker cover. Connect vacuum lines to throttle body port. Connect large PCV vacuum line to throttle body. Connect large PCV vacuum line to upper manifold. Connect manifold vacuum connections, including rear connection to vacuum tee, front connection to fuel pressure regulator and air cleaner.
- Connect accelerator and speed control cables. Install air supply tube and tighten clamps. Connect wiring harness at ECT sensor in heater supply tube, and Electronic Engine Control harness. Connect the fuel supply hose from the fuel filter to the fuel rail. Connect the fuel return line. Connect battery ground and refill cooling system.