Figure 78 does not show the four
bolts on the other side of the intake
manifold.

Figure 78



Push down enough for the O-rings
to hold the bolts in place, but not
enough for the bolts to stick out the
bottom (see Figure 79).

Push
O-ring in

Figure 79

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24. Remove all plugs shown in Figure 80
now.

Flange



Do not remove the cap on the air
inlet connection assembly.



Plugs can be reused. Put them back
in Kit J-54423 (see page 2).



Position the rotary turbine control
valve linkage as far as possible on
the driver side of the EGR bypass
flange.

Linkage

Do not
remove
yet

Figure 80
25. Put the intake manifold in place (no picture shown).


Make sure:
 All intake manifold O-ring gaskets are properly seated.
 The engine control harness is not being pinched by the intake manifold.
 The EGR bypass coolant tube and both water transfer connection tubes are
properly positioned and inserted (see next page, Figure 84).
 All bolts thread in/start by hand.
CAUTION: Due to its weight and location, use proper lifting equipment or assistance
when lifting and installing the intake manifold assembly.
26. Torque the bolts.



Bolts torque: 18 N•m (1.8 kg-m, 13 ft-lbs)
See Figure 81 for torque sequence.

Figure 81

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27. Connect the EGR temperature sensor
connector (see Figure 82 and 83).


This sensor is located under the
front of the intake manifold.

Hidden
EGR temp
sensor
connector
Figure 82



Figure 83 shows the EGR
temperature sensor connector when
viewed between the front of the
intake manifold and the air inlet
connection assembly.

Hidden
EGR temp
sensor
connector

Cap - Air inlet
connection
assembly
Figure 83

Paint
mark

28. Install the bolts for the EGR bypass
coolant tube and both water transfer
connection tubes (see Figure 84).


Bolts torque: 7.4 N•m (0.75 kg-m,
65 in-lbs)

Figure 84

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29. Install the air intake connection bolt (see
Figure 85).


Bolt torque: 18 N•m (1.8 kg-m,
13 ft-lbs)

Figure 85

30. Install the air inlet connection bolt (see
Figure 86).


Bolt torque: 18 N•m (1.8 kg-m,
13 ft-lbs)

Figure 86

31. Remove the tape, and then connect
the air outlet hose to the air intake
connection (see Figure 87).


Clamp nuts torque: 10 N•m
(1.0 kg-m, 84 in-lbs)

Figure 87

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32. Install the three (3) EGR valve inlet pipe
bolts (see Figure 88).


Hidden
bolt

Bolts torque: 23 N•m (2.3 kg-m,
17 ft-lbs)
 Replace the gasket. Do not reuse
the old gasket.
NOTE: There are extra bolts in the
parts kit. Replace as needed.

Figure 88

33. Install the three (3) EGR bypass tube
bolts (see Figure 89).


Linkage
and bolt

Hidden
bolt

Bolts torque: 18 N•m (1.8 kg-m,
13 ft-lbs)
 Apply suitable anti-seize to the
bolt’s threads before installing.
 Make sure the gasket has been
replaced (see page 36, step 22).
Do not reuse the old gasket.
NOTE: There are extra bolts in the
parts kit. Replace as needed.

Figure 89

34. Mount and secure the rotary turbine
control valve upper linkage (see Figure
89 and 90).


EGR
valve
actuator

Bolt torque: 10 N•m (1.0 kg-m,
84 in-lbs)

Connector

35. Connect the EGR valve actuator
connector (see Figure 90).

Linkage
and bolt

Figure 90

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36. Install the exhaust pressure sensor tube
(see Figure 91 and 92).


Replace the O-ring with a new one.
 Coat the O-ring with P80
Emulsion (see CAUTION under
PARTS INFORMATION).



Fully insert the tube in the intake
manifold first.



Bolt 1 and 2 torque: 7 N•m (0.7 kg-m,
62 in-lbs)



Flare nut torque: 19 N•m (1.9 kg-m,
14 ft-lbs)
NOTE: The flare nut torque
specification is an adjusted value
when using a torque wrench 11-15
inches long and a flare nut type
“crow’s foot” 1-1.5 inches long.
 The “crow’s foot” is measured
from the center of the square
hole to the center where the
flare nut fits (see Figure 93).

Dipstick tube plug
Tube

Exhaust
pipe end

Bolt 2

Flare nut

Figure 91

Bolt 1

1-1.5 inches

Tube

Intake
manifold end

Bolt 2
Figure 92

Figure 93
Bolt
37. Mount the stage 2 fuel filter assembly
with the one bolt (see Figure 94).


At this time, install the bolt finger
tight.
Figure 94

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38. Install the oil dipstick with tube.
a. Remove the plug (see Figure 95).
b. Install a new O-ring on the oil dipstick
tube.
 Coat the O-ring with engine oil.
c. Insert the oil dipstick tube into the first
engine block hole.
d. Guide the oil dipstick tube further into
the first hole at an angle, and then into
the second engine block hole until fully
seated (see Figure 95, 96 and 97).
e. To verify the oil dipstick tube is
properly installed, check the engine oil
level.
 If the oil level registers the same
as recorded on page 12, step 14,
the oil dipstick tube is properly
installed.
 If NO oil registers, the oil dipstick
tube missed the second engine
block hole. Remove and correctly
install.
CAUTION: The oil dipstick tube
goes through the converter housing
area before entering the second
engine block hole. It is possible to
insert the oil dipstick tube in the
converter housing area and not the
second engine block hole.
f. When the oil dipstick tube is fitted
correctly, install the bolt (see
Figure 98).
 Bolt torque: 7.4 N•m (0.75 kg-m,
65 in-lbs)

Plug

Figure 95

Figure 96

Rear of
engine block
1st
hole

Oil dipstick
tube

Rear of
turbochargers

Bolt
2nd
hole
Figure 98

Figure 97

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39. Carefully cut, and then remove the tie
strap (see Figure 99).
Plug
Fuel line
Tie strap
40. Remove the plug and cap, and then
connect the fuel line to the stage 2 fuel
filter assembly (see Figure 99, 100, and
101).

Figure 99

Cap

Figure 100

41. Install the four (4) bolts. See Figure 101.
NOTE: Two of the bolts also secure the
stage 2 fuel filter assembly.


Stage 2 fuel filter assembly bolts
torque: 18 N•m (1.8 kg-m, 13 ft-lbs)
Bolts

 Also apply the torque above to the
bolt shown on page 41, Figure 94.


Remaining bolts torque: 7.4 N•m
(0.75 kg-m, 65 in-lbs)

42. Snap the two fuel lines in their clips (see
Figure 101).

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Fuel
Fuellines
line
and
clips
clips
Figure 101

NTB16-097

Bolt

43. Connect the breather tube to the valve
cover, and then install the clamp and bolt
(see Figure 102).


Bolt torque: 7.4 N•m (0.75 kg-m,
65 in-lbs)

Clamp
Breather
tube

44. Route the engine control harness, and
then connect and lock all the related
connectors (see Figure 103).


Valve
cover

Figures 104-106 shows how to secure
the different types of connectors.

Figure 102

EGR valve
actuator
Push
tab in
2

Push
1 connector on

Harness
Figure 103

1

Figure 104

Push
connector on

2

Push
lock in

Push
connector on

Figure 105

Figure 106

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45. Remove the cap, install the air filter element, and then install the air duct with upper air
cleaner case (see Figure 107 and 108).


Make sure to connect the mass air flow sensor and turbocharger compressor intake
pressure/temperature sensor.

Install
Remove

Remove
Figure 107

Figure 108

46. Install all three (3) heat shields, center heat shield last (see Figure 109).


The vehicle will need to be raised to access some of the bolts.



Bolts torque: 7.4 N•m (0.75 kg-m, 65 in-lbs)

1

2

3

Figure 109
1. Center heat shield

2. RH heat shield

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3. LH heat shield

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47. Install the cowl.
a. Install the cowl top extension with the eight (8) bolts, and then install both drain
pipes (see Figure 110, # 3 & 5, and Figure 112 and 113).


Bolts torque: 5.5 N•m (0.56 kg-m, 49 in-lbs)

b. Install the wiper drive assembly (see Figure 111).


Bolts torque: 5.74 N•m (0.59 kg-m, 51 in-lbs)

