Removal and Installation

Intake Manifold

Removal
1. Disconnect the battery ground cable.
2. Remove the engine cover.
3. Disconnect the fuel lines.
4. Drain the cooling system.





5. Reposition the Engine Air Cleaner (ACL).
1 Remove the four bolts.
2 Loosen the clamp.
3 Position the ACL to gain access to the Mass Airflow (MAF) sensor electrical connector.





6. Disconnect the MAF sensor electrical connector and remove the ACL.





7. Disconnect the two hoses.





8. Loosen the clamp and remove the air cleaner outlet pipe.





9. Compress and slide the hose clamp and disconnect the upper radiator hose.





10. NOTE: Typical is shown.

Disconnect the throttle body control linkage.
1 Disconnect the accelerator cable.
2 Disconnect the speed control actuator cable.
3 Disconnect the throttle control return spring.





11. NOTE: Typical is shown.

Remove the bolts retaining the accelerator cable bracket to the throttle body.

Remove the accelerator cable bracket.





12. NOTE: Typical is shown.

Disconnect the connector from the Throttle Position (TP) sensor.





13. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR) system.
^ Disconnect the electrical connector.
^ Remove the system and hoses from the exhaust manifold to EGR valve tube.





14. Remove the exhaust manifold to EGR valve tube.
^ Disconnect the upper and lower fittings.
^ Remove the tube.





15. Disconnect the EGR vacuum regulator solenoid electrical connector.





16. Disconnect the following vacuum hoses:
^ The brake booster hose.
^ The Positive Ventilation (PCV) valve tube.





17. Remove the two evaporative emission canister purge valve nuts and position the valve aside.





18. Disconnect the IAC valve electrical connector.





19. Disconnect the following vacuum connections:
1 EGR valve vacuum hose.
2 Engine vacuum supply hose.
3 EGR vacuum regulator solenoid vacuum hose.
4 Fuel pressure regulator vacuum hose.
5 Evaporative emission canister purge valve vacuum hose.





20. Remove the four bolts, and the throttle body and adapter as an assembly.
^ Discard the throttle body adapter gasket.





21. NOTE: LH shown, RH similar.

Disconnect the eight coil-on-plug electrical connectors.





22. NOTE: RH shown, LH similar.

Disconnect the eight fuel injector electrical connectors.





23. NOTE: LH shown, RH similar.

Remove the bolts and the eight ignition coils.





24. Remove the bolts and the generator upper support bracket.





25. Disconnect the hose clamp and remove the heater water hose.





26. NOTE: Typical is shown.

Remove the bolts, water thermostat housing and thermostat.
^ Discard the O-ring seal.





27. Remove the nine bolts.





28. Remove the intake manifold assembly.
1 Lift the intake manifold.
2 Disconnect the intake manifold tuning valve connector.
3 Remove the intake manifold and discard the gaskets.
^ Inspect the intake manifold assembly for damage.


Installation

1. CAUTION: Do not use metal scrapers, power abrasive discs or any abrasive means to clean the sealing surfaces, these tools cause scratches and gouges that make leak paths. Use a plastic scraper only.

Clean all the sealing surfaces.





2. Install the upper intake manifold.
1 Position the new intake manifold gaskets.
2 Position the upper intake manifold.
3 Loosely install nine bolts.





3. Connect the intake manifold tuning valve electrical connector.





4. Install the water thermostat.
1 Install the thermostat.
2 Install a new O-ring seal.





5. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.

Install the thermostat housing and loosely install the bolts.





6. Tighten the 11 bolts in two stages in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).





7. Install the heater water hose and position the clamp.





8. Install the generator upper support bracket.





9. NOTE: LH shown, RH similar.

Install the eight ignition coils and bolts.





10. NOTE: LH shown, RH similar.

Connect the eight fuel injector electrical connectors.





11. NOTE: LH shown, RH similar.

Connect the eight coil-on-plug electrical connectors.





12. Position a new throttle body adapter gasket and install the throttle body adapter assembly.





13. Connect the following vacuum connections:
1 EGR valve vacuum connector.
2 Engine vacuum supply vacuum connector.
3 EGR vacuum regulator solenoid vacuum connector.
4 Fuel pressure regulator vacuum connector.
5 Evaporative emission canister purge valve vacuum connector.





14. Connect the IAC electrical connector.





15. Install the evaporative emission canister purge valve and bracket.





16. Connect the following vacuum hoses:
^ The brake booster hose.
^ The Positive Crankcase Ventilation (PCV) valve tube.





17. Connect the EGR vacuum regulator solenoid electrical connector.





18. Install the exhaust manifold to EGR valve tube.
^ Hand-tighten the upper and lower fittings. Tighten the fittings to 35 - 45 Nm (26 - 33 ft. lbs.).





19. Install the differential pressure feedback EGR system. Install the system and hoses on the exhaust manifold to EGR valve tube. Connect the electrical connector.
20. Connect the fuel lines.





21. NOTE: Typical is shown.

Connect the TP sensor electrical connector.





22. NOTE: Typical is shown.

Position the accelerator cable bracket and install the bolts.





23. NOTE: Typical is shown.

Connect the throttle body control linkage.
1 Connect the accelerator cable.
2 Connect the speed control actuator cable.
3 Connect the throttle control return spring.





24. Install the upper radiator hose and reposition the clamp.





25. Install the air cleaner outlet pipe and tighten the clamp.





26. Connect the two hoses to the air cleaner outlet pipe.





27. Connect the MAF sensor and position the ACL.





28. Install the ACL.
^ Install the four bolts.
^ Tighten the clamp.
29. Install the interior engine cover.
30. Connect the battery ground cable.
31. Fill and bleed the engine cooling system.