Intake Manifold: Service and Repair

Removal

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury.

1. Remove the charge air cooler.
2. Disconnect the fuel lines.
3. Drain the engine cooling system.

4. Remove the bolt.

5. Loosen the bolts and position the bracket aside.

6. Disconnect the upper radiator hose.

7. CAUTION: Do not disconnect the PCV hose system from the intake. Installation can not be carried out with the intake in place.

Disconnect the Positive Crankcase Ventilation (PCV) system.

8. Disconnect the ground strap and both radio ignition interference capacitors.

9. Disconnect the vacuum line.

10. Disconnect the charge air cooler temperature sensor.

11. Disconnect the heater hose.

12. Disconnect the hoses.

13. Disconnect the eight fuel injector electrical connectors.

14. Disconnect the vapor management valve vacuum line.

15. Disconnect the vacuum line near the brake vacuum booster.

16. Remove the fuel injection supply manifold.

17. Disconnect the eight ignition coil connectors.

18. Remove the eight ignition coils.
19. Release the tension from the accessory drive belt.

20. Remove the generator bracket.

21. Remove the intake manifold.

22. Remove the gaskets.

23. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to clean the sealing surfaces.

Clean the sealing surfaces.

Installation

1. Position the gaskets.

2. CAUTION: If the PCV system hose becomes disconnected, the intake manifold will have to be removed to reattach the hose.

Make sure that the PCV system hose is securely connected.

3. Install the intake manifold.
- Position the manifold.
- Position the thermostat outlet.
- Install the bolts. Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 inch lbs.).
- Stage 2: Tighten to 25 Nm (19 ft. lbs.).