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Intake Plenum: Installation

NOTE: Make sure that gasket face is clean of any old gasket material.
  1. Install a new gasket then position intake plenum on intake manifold.
  2. Install five Allen-head intake plenum bolts. See Figure . Tighten intake plenum bolts to specification. See TORQUE SPECIFICATIONS  .
  3. Connect front breather tube to front rocker arm cover. See Figure .
  4. Position front breather tube on intake plenum, and install two front breather tube bracket-to-intake plenum bolts. Tighten two front breather tube bracket-to-intake plenum bolts.
  5. Position ground wires on intake plenum then install two ground wire bolts. See Figure . Tighten ground wire bolts to specification. See TORQUE SPECIFICATIONS  .
  6. Connect main engine wiring harness clips on breather tube brackets.
  7. Connect fuel pressure regulator-to-intake manifold vacuum line on fuel pressure regulator.
  8. Connect Idle Air Control-Fast Idle Control (IAC-FIC) assembly connectors. See Figure .
  9. Connect Bypass Air (BPA) valve electrical connector.
  10. Connect Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector, if equipped.
  11. Install Exhaust Gas Recirculation (EGR) pipe on EGR valve. Tighten Exhaust Gas Recirculation (EGR) pipe fitting.
  12. Connect brake booster vacuum hose on side of intake plenum. See Figure .
  13. Position accelerator/speed control cable bracket on intake plenum.
  14. Install two accelerator/speed control cable bracket bolts. Tighten accelerator/speed control cable bracket bolts to specification. See TORQUE SPECIFICATIONS  .
  15. Install accelerator cable on bracket attached to top of intake plenum.
  16. Install speed control cable in hanging support, if equipped.
  17. Connect accelerator cable on throttle lever. See Figure .
  18. Connect speed control cable on throttle lever, if equipped.
  19. Install wiring harness bracket on side of intake plenum.
  20. Connect rear heater valve vacuum hose on side of intake plenum, if equipped. See Figure .
  21. Install distributor cap on distributor and tighten three distributor cap screws.
  22. Install distributor dust cover.
  23. Install two spark plug brackets and bolts on intake plenum.
  24. Connect No. 1, 3, and 5 spark plug wires on spark plugs.
  25. Connect carbon canister-to-intake plenum vacuum hose. See Figure .
  26. Position EGRC bracket on intake plenum, and install two EGRC bracket bolts.
  27. Connect EGR valve-to-EGRC solenoid vacuum hose.
  28. Connect EGRC solenoid-to-throttle body vacuum hose.
  29. Remove plug and connect coolant hose to top heater pipe.
  30. Remove plug and connect front throttle body coolant hose.
  31. Connect idle switch electrical connector.
  32. Install TP sensor electrical on EGRC bracket.
  33. Connect Throttle Position (TP) sensor electrical connector.
  34. Install air duct resonance chamber. See AIR DUCT  .
  35. Connect negative battery cable.
  36. Fill and bleed air from cooling system. See COOLANT REFILLING  .
  37. Start engine and check for proper operation.
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