DORMAN 615-188 Engine Intake Manifold Installation Guide
- June 1, 2024
- DORMAN
Table of Contents
DORMAN 615-188 Engine Intake Manifold
Product Information
Specifications:
- Product Name: Intake Manifold 615-188
- Installation Manual: 615-188 Tech Note
- Tightening Specifications:
- Stage One: 2 Nm (18 in-lbs)
- Stage Two: 25 Nm (18 ft-lbs)
Product Usage Instructions
Before You Begin:
Before starting the installation process, ensure that you have read and understood the factory service manual. If you are unsure about performing the necessary procedures correctly, seek the services of a qualified technician.
Step 1: Removal of Intake Manifold
Carefully remove the intake manifold following the service procedure
outlined in the factory service manual.
Step 2: Cleaning
Clean all mounting surfaces thoroughly to ensure proper adhesion of the new
intake manifold.
Step 3: Installation
Install the new intake manifold according to the instructions provided in
the factory service manual.
Step 4: Tightening Intake Bolts
Tighten the intake bolts in two stages:
- Stage One: Tighten to 2 Nm (18 in-lbs)
- Stage Two: Tighten to 25 Nm (18 ft-lbs)
Step 5: Bolt Installation Sequence
Follow the sequence shown in the manual for installing the intake bolts to
ensure proper alignment and sealing.
FAQ (Frequently Asked Questions):
-
Q: Do I need any special tools for installing the intake manifold?
A: The installation of the intake manifold typically requires standard mechanic tools such as wrenches and sockets. Refer to the factory service manual for any specific tool requirements. -
Q: Can I reuse the old intake manifold gasket?
A: It is recommended to install a new intake manifold gasket when replacing the intake manifold to ensure proper sealing and prevent leaks.
BEFORE YOU BEGIN
- Always wear proper safety equipment when performing repairs.
- Ensure this part fits your exact vehicle year, make, model and configuration. You can verify at your point of purchase using the part number on the box, or using the part number above at DormanProducts.com.
- Reference the appropriate service manual for your vehicle. If you do not have a service manual, and do not have the training or experience to perform the necessary procedures correctly, seek the services of a qualified technician.
Installation
This intake manifold design does not require additional intake gaskets. The intake gaskets are already installed into the manifold.
- Be sure to fully seat the injectors into intake manifold when installing the fuel rail. Failure to do so will result in a vacuum leak and/or may prevent fuel rail from being properly attached.
- There are two sizes of thread-forming screws:
- The small thread-forming screws are used for mounting the ignition coils. Tighten to 2.7 to 3.3 Nm (2 to 2.4 ft-lbs) torque. DO NOT OVERTIGHTEN!
- The large thread-forming screws are to be tightened to 6 to 7 Nm (4 to 5 ft-lbs). DO NOT OVERTIGHTEN!
- To install fuel rail fasteners, start each large fastener for three full rotations before tightening any fastener completely.
- Some large self-tapping screws provided may not be used in your application. The number of fasteners used will vary based upon vehicle application.
- Transferring Noise, Vibration and Harshness (NVH) cover from original manifold is not required if replacement manifold is provided with one.
- Provided in the component kit will be an auxiliary coolant fitting that has sealant pre-applied to the threads. The installed plug must be removed only for original applications that require an additional coolant connection. The provided auxiliary coolant fitting should be installed and tightened to no more than 10 Nm (7 ft-lbs). DO NOT BOTTOM OUT FITTING!
- STEP 1: Carefully remove intake manifold per the service procedure outlined in factory service manual.
- STEP 2: Clean all mounting surfaces.
- STEP 3: Install new intake manifold per factory service manual.
- STEP 4: Tighten intake bolts as follows:
- Stage One: 2 Nm (18 in-lbs)
- Stage Two: 25 Nm (18 ft-lbs)
- STEP 5: Install intake bolts in sequence shown
Kit Contents
Auxiliary Coolant Fitting
Installed plugs should only be replaced by customers that require a second coolant connection. Install fitting. Do not exceed 10 Nm (7 ft-lbs) torque. 1–3 threads will be showing for properly installed fitting. DO NOT BOTTOM OUT FITTING!
Disclaimer:
Even though every attempt is made to ensure this information is complete and
accurate, it is impossible to account for all possible circumstances or
situations. Please consult with a qualified auto technician before attempting
to perform any work you are not qualified to do. Automobiles can be hazardous
to work on; be sure to take all necessary safety precautions. Failure to do so
may result in property damage or personal injury. Certain motor vehicle
standards and performance requirements may apply to your motor vehicle (such
as Federal Motor Vehicle Safety Standards by the National Highway Traffic
Safety Administration). Be sure that your work is performed by such standards
and that you do not disable any motor vehicle safety feature.
Dorman Products, Inc.
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