PI-393 • 07/10

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Installation Instructions PI393

Phenolic Spacer
All 850 Models, S/V/C 70 series 1998 only
ipd #25.0025

SUGGESTED TOOLS
• Metric Wrenches • Metric Sockets • Rachet • Flat Blade Screwdriver

Safety Warnings !
• Always support the vehicle with jack stands before working underneath
• Use only the parts supplied by ipd to install this kit
• Check ALL the fasteners for tightness before and after road testing the vehicle
• Do not use air impact wrench when re-installing bolts as stripped threads may resul

REMOVAL
1 Read instructions completely before starting work.

2 Ensure the engine is completely cooled off before proceeding with installation. Do not start installation
on a warm or hot engine.

11744 NE Ainsworth Circle, Portland, OR 97220 • (503) 257-7500 • Fax (503) 257-7596
INSTALLATION
3 Locate and remove the torx 25 fastener on the throttle cover and remove it and the cover.

4 Remove the fuel injector cover by pulling it away from the engine toward the front of the car.

5 Disconnect the injector harness for all 5 injectors.

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 INSTALLATION
6 Remove the air intake tube by squeezing the end
and pulling it free from the core support.

7 Loosen the two clamps on the upper intercooler outlet tube (7mm).

8 Remove the upper intercooler outlet tube.

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INSTALLATION
9 Remove the oil dipstick and transmission dipstick to prevent accidental breakage, note the level of
engine oil on the dipstick.

10 Remove the cap from the fuel injector rail test

port.

*The next step involves relieving the fuel pressure from the fuel rail, if you are inexperienced in this
process consult a service manual for more information*
11 Using a flat blade screwdriver gently press the Schrader valve in the fuel rail, use a shop towel to
absorb the fuel as it exits the rail.

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 INSTALLATION
12 Use a 17mm and 14mm wrench to loosen the fuel
inlet line.

13 Use a flat blade screw driver to loosen the clamp

on the fuel return line.

14 Remove the fuel return line from the fuel rail.

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INSTALLATION
15 Remove the two 10mm bolts from the fuel rail.

16 Remove the fuel rail with injectors from the intake

manifold. Using a pair of needle nose pliers you
can gently persuade each of the injectors loose of
the intake manifold then remove the assembly.

17 Finally remove fuel pressure regulator vacuum

line from the vacuum tree and set the fuel rail
and injector assembly aside.

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18 Remove the six torx 30 screws holding the top
engine cover in place.

19 Remove the top engine cover.

20 Remove the ventilation hose from the top of the

engine as shown.

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21 For cars with EGR remove the egr pipe using a
22mm wrench.

22 For cars with EGR remove the EGR temp sensor

connector.

23 There are 7 bolts holding the intake manifold to the engine, only the top row of bolts require removal,
the intake manifold lower bolt holes are slotted so the manifold can lift off them even while they are
still screwed into the cylinder head.

24 Loosed all 7 bolts and remove the three bolts on the top row of the intake manifold. You can use a
10mm wrench and socket to access them as shown.

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25 The far left bolt on the manifold can seem difficult
to reach, a straight socket extension and shallow
socket are necessary.

26 Remove the 12mm bolt holding the oil dip stick

tube in place.

27 Remove the dipstick tube from the engine.

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INSTALLATION
28 Remove the 12mm bolt holding the intake
manifold to its support bracket, it is hard to see so
you’ll be working blind. Note the angle and depth
of the wrench in the picture for reference to the
bolts location.

29 Lift the manifold up slightly to access the vacuum

line on the passenger side and remove it.

30 Now slip the upper engine ventilation hose down

through the manifold as shown.

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 INSTALLATION
31 Lift the manifold up and using a cord or strap secure it up out
of the way, pay attention to the remaining vacuum lines and
position of the manifold so you have room to work without
stressing the lines as they may be brittle from age.

32 Remove the remaining intake manifold bolts and

intake manifold gasket.

33 Locate the intake manifold support bracket,

remove the 12mm bolt holding it to the engine
block.

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34 Using the included bolt, washer and spacer install
the intake manifold support bracket back to the
engine as shown torque to 15 ft lbs.

35 Install the new gaskets and Ipd intake manifold

spacer as shown, do not install the top row of
three bolts at this time.

36 Lay the intake manifold back into position and

guide the upper engine ventilation hose in
between the #1 and #2 cylinder runners.

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 INSTALLATION
37 Reconnect the vacuum line to the passenger side
vacuum port on the end of the intake manifold.

38 Position the intake manifold onto the lower row

of bolts and install the 3 bolts on the top row by
hand, Do not fully tighten at this time.

39 Reconnect the upper engine ventilation hose to its

port, cut the old clamp off with cutters, and using
the supplied clamp fasten it in place.

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40 Reinstall the 12mm bolt to the intake manifold support bracket, tighten to 15 ft lbs

41 Tighten the 7 intake manifold bolts to 14 ft lbs

42 Reinstall the EGR pipe and tighten firmly for cars equipped

43 Reconnect the EGR temp sensor connector for cars equipped

44 Reinstall the oil dipstick tube with the supplied O-ring and its 12mm bolt. Tighten to 12 ft lbs

45 The spacing of the manifold will move the dipstick tube away from the block by 10mm, this can
be combated by reinstalling the dipstick tube slightly rotated clockwise and adjusting the bracket
downward by approx 0.250 inch.

46 Reinstall the fuel rail and injectors, use some light lubricant to lubricate the injector o-rings prior to
installation.

47 Reconnect the fuel pressure regulator vacuum line to the vacuum tree

48 Reinstall the two 10mm bolts to the fuel rail and tighten to 8 ft lbs

49 Reconnect the injector harness to all 5 injectors.

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 INSTALLATION
50 Reconnect the fuel inlet line using a 17mm and 14mm wrench

51 Reconnect the fuel return line and secure it’s clamp

52 Reinstall the top engine cover and it’s 6 torx 30

fasteners, tighten to 7 ft lbs.

53 Reinstall the fuel injector cover.

54 Reinstall the intercooler outlet tube and tighten its

two clamps.

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INSTALLATION
55 Reinstall the throttle cover and its torx 25 screw

56 Reinstall the air inlet tube

57 Reinstall the transmission dipstick

58 Reinstall the dipstick and check the level. Compare to the reading taken before and adjust the
dipstick tube downward if necessary until the new reading matches

warranty
One Year Limited Warranty
ipd warrants to the original purchaser that the parts manufactured and/or sold by ipd (the Product) is free from defects in material and
workmanship under normal use. ipd warrants that the Product will perform substantially in accordance with the specifications set forth in
the documentation provided with it. The above express warranties are made for a period of the lesser of 12,000 miles or 12 months from the
date the Product is installed in your vehicle.

Any improper use, operation beyond capacity, substitution of parts not approved by ipd in writing, any alteration or repair by others, or
any removal, defacing or altering of the identification shall void this warranty. There is no warranty on high-performance or race related
parts due to the nature of usage.

The purchaser shall notify ipd at 1-800-444-6473 of any defect within the warranty period no later than thirty (30) days after purchaser
discovers the defect. Should any failure to conform to this warranty appear within the warranty period, ipd shall, on notification, correct
the nonconformity at its option, either by repairing any defective part, or by making available, FOB ipd’s plant, a repaired or replacement
part. The purchaser must insure any defective item being returned because ipd does not assume risk of loss or damage while in transit. No
payment or reimbursement shall be made for installation, removal, transportation or other charges. The remedies set forth in this instrument
are exclusive, and the liability of ipd with respect to any sale shall not exceed the price of the product on which the liability is based.

EXCEPT AS STATED OTHERWISE IN THIS WARRANTY, ipd MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied
warranty lasts, so the above limitation may not apply to you. ipd shall not in any case be liable for special, incidental, consequential,
indirect, or other similar damages arising from any breach of these warranties even if ipd or its agent has been advised of the possibility
of such damages. Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or
exclusion may not apply to you.

This warranty is governed by the laws of the State of Oregon.

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