Removal and Installation of Intake Manifold

REMOVAL

^ TOOLS Required - J 34730-1A Fuel Pressure Gauge, or equivalent.





1. Disconnect the negative battery cable.
2. Raise the vehicle and support.
3. Drain the cooling system.
4. Lower the vehicle.





5. Disconnect the intake air temperature sensor connector.
6. Disconnect the manifold absolute pressure sensor connector.





7. Disconnect the fuel regulator purge line from the air intake duct.
8. Remove the air intake duct and air cleaner assembly.





9. Remove the fuel rail covers.
10. Relieve the fuel system pressure using fuel pressure gauge.

CAUTION: Cap the fittings and plug the holes when separative fuel system components in order to prevent dripping of fuel and/or dirt and other contaminants from entering the fuel system.





11. Disconnect the fuel lines from the fuel rail (3, 4).
12. Remove the vacuum and crankcase vent hoses.
13. Remove the throttle body coolant outlet hose from the throttle body.





14. Disconnect the fuel injector connectors.
15. Disconnect all the remaining electrical connections from the intake manifold.
16. Remove the intake manifold.

INSTALLATION

WARNING: The fuel rail stop bracket must be installed onto the intake manifold assembly. The stop bracket serves as a protective shield for file fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.

Intake Manifold Bolt Tightening Sequence:

1. Install the intake manifold bolts and fuel rail stop bracket.
a. Tighten intake manifold bolts first pass in sequence to 5 Nm (44 inch lbs.).
b. Tighten intake manifold bolts final pass in sequence to 8 Nm (89 inch lbs.).





2. Connect the fuel injector wire harness connectors.
3. Connect all remaining electrical connections to the intake manifold.





4. Install the fuel lines to the fuel rail (3, 4).





5. Install the fuel rail covers.





6. Install the air intake duct and air cleaner assembly.
7. Connect the fuel regulator purge line to the air intake duct.





8. Connect the manifold absolute pressure sensor connector.
9. Connect the intake air temperature sensor connector.
10. Fill the cooling system.
11. Connect the negative battery cable. Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.).