Removal and Installation

Intake Manifold

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, resulting in possible personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running.

1. Disconnect the battery ground cable.
2. Remove the air cleaner assembly and tubes.
3. Drain the coolant system.
4. Disconnect the fuel lines.





5. Compress and slide the hose clamp and disconnect the water outlet hose.





6. Remove the engine vacuum harness. Disconnect the harness as shown.
1 Exhaust Gas Recirculation (EGR) valve, if equipped
2 EGR vacuum regulator solenoid, if equipped
3 vacuum source
4 fuel pressure regulator
7. Remove the throttle body.
8. Remove the bolts, the throttle body adapter, and the gasket.





9. If equipped, disconnect the Exhaust Gas Recirculation (EGR) valve to exhaust manifold tube lower fitting.





10. Disconnect the five RH fuel injector electrical connectors.





11. Disconnect the five LH fuel injector electrical connectors.





12. Disconnect the water temperature indicator sender with electrical connectors.
13. Disconnect and remove the 10 ignition coils.
14. Remove the Generator (GEN).





15. Disconnect the heater water hose.
16. Remove the water thermostat.





17. Remove the bolts, the upper intake manifold and the intake manifold gaskets Discard the intake manifold gaskets.





18. Separate the upper and lower intake manifolds.
^ Remove the 10 bolts.
^ Discard the intake manifold gasket.
19. Clean all mating surfaces.

Installation





1. Position the lower intake manifold gasket and the upper intake manifold on the intake manifold and loosely install the 10 bolts.





2. NOTE: Tighten the bolts in two stages.

Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).





3. Install the upper intake manifold.
^ Position the upper intake manifold gaskets and the intake manifold, and loosely install the bolts.





4. NOTE: Be sure to tighten the bolts in two stages.

Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
5. Install the thermostat.
6. Install the throttle body adapter gasket and the throttle body adapter. Tighten the bolts in two stages:
^ Stage 1: Tighten the bolts to 9 Nm.
^ Stage 2: Tighten the bolts an additional 90° (1/4 turn).

7. NOTE: Leave the engine cover off.

Install the throttle body.





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





9. Connect the water temperature indicator sending unit electrical connector.
10. Install the generator.
11. Install the ignition coils.





12. Connect the five LH fuel injector electrical connectors.





13. Connect the five RH fuel injector electrical connectors





14. Connect the engine emission vacuum harness.
1 EGR valve, if equipped
2 EGR vacuum regulator solenoid, if equipped
3 vacuum source
4 fuel pressure regulator





15. If equipped, connect the EGR valve to exhaust manifold tube lower fitting.
16. Connect the fuel lines.





17. Connect the engine water outlet hose and position the hose clamp.
18. Install the air cleaner assembly and tubes.
19. Fill the cooling system.
20. Install the engine cover.
21. Connect the battery ground cable.