Fuel Charging Assembly: Installation

1. Clean and inspect mounting faces of 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.
2. Install fuel return line in fuel supply manifold. Install 2 manifold mounting nuts fingertight. Install remaining 3 manifold mounting nuts and tighten all nuts. Connect upper and lower manifold support brackets and tighten bolts. Install EGR tube with oil coated compression nut.
3. Connect vacuum lines to throttle body port. Connect large PCV vacuum line to upper manifold. Reconnect all manifold vacuum lines. Connect accelerator and speed control cables. Install air supply tube and tighten clamps.
4. Reconnect wiring harness at ECT sensor and EEC harness. Connect fuel supply hose from fuel filter to fuel rail. Connect fuel return line. Connect battery ground and refill cooling system.

1. Clean both mounting faces. Surfaces must be clean and flat. Clean and lubricate manifold stud threads. Install new gasket. Position lower manifold assembly on head. Install engine lifting bracket. Install 4 upper manifold retaining nuts fingertight. Install 4 remaining manifold nuts. Tighten all nuts in correct sequence. See Fig 1 .
   Fig 1: 2.3L Turbo Intake Manifold Tightening Sequence

   
2. Install fuel supply manifold with 2 retaining bolts. Tighten bolts. Connect wiring to injectors. Make sure gasket surfaces are clean on both manifolds. Place new gasket on lower intake manifold assembly and place upper intake manifold in position. Install retaining bolts and tighten in sequence. See Fig 1 .
3. Install injector pulse mounting bracket and engine oil dipstick. 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 PCV system hose to fitting on underside of upper intake manifold. Connect all upper intake manifold vacuum connections, including rear vacuum line from dash panel to vacuum tee, EGR valve and fuel pressure regulator.
4. Hold accelerator cable bracket in position on upper manifold and tighten retaining bolt. Install accelerator cable in bracket. Position cast tube gasket on turbocharger. Be sure surfaces of cast tube and turbocharger are clean. Position new gasket on throttle body mounting flange of fuel charging assembly.
5. Install cast tube/air throttle body assembly on turbocharger, making sure gasket is in correct position. Install 2 cast tube retaining bolts and tighten. Attach air throttle body/cast tube assembly to fuel charging assembly. Install 2 retaining nuts and 2 bolts. Tighten in sequence. See Fig 1 . Connect accelerator cable.
6. Connect wiring at air by-pass valve, TPS, CTS, injector wiring harness, detonation (knock) sensor and fan temperature sensor. Connect battery ground. Refill cooling system. Start engine and check for leaks.

Clean both mounting surfaces. Make sure surfaces are flat. Clean and oil stud threads. Install new gasket. Install air intake/throttle body assembly, making sure that guide pins are properly aligned. Install 1 stud bolt and 5 regular bolts and hand tighten evenly. Tighten all 6 bolts evenly, starting from either short center bolt and working out to bolts on either end.

Make sure mounting faces are clean and flat. Position new gasket and install upper manifold with throttle body onto lower manifold. To complete installation, assemble all parts in reverse order of removal. If lower intake manifold was loosened or removed, fill and bleed cooling system.