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. Failure to follow these instructions may result in personal injury.

1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet pipe.
3. Drain the engine cooling system.





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





5. Disconnect the throttle body cam.
1 Disconnect the accelerator cable.
2 Disconnect the speed control actuator cable.
3 Remove the accelerator return spring.





6. Remove the accelerator cable bracket bolts and position the bracket and cables aside.





7. Remove the Idle Air Control (IAC) fresh air hose.





8. Disconnect the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid connections.





9. Disconnect the IAC and Throttle Position (TP) sensor electrical connectors.





10. Disconnect the EGR valve vacuum hose and the evaporative emission canister purge valve hose and position them aside.





11. Disconnect the fuel pressure regulator vacuum hose.





12. Disconnect the differential pressure feedback EGR system electrical connector.





13. Disconnect the evaporative emission canister purge valve vacuum hose.





14. Remove the nut and disconnect the brake booster vacuum tube and position the bracket and tube aside.





15. Position the crankcase ventilation hose aside.





16. Position the exhaust manifold to EGR valve tube aside.
^ Disconnect the upper fitting.
^ Loosen the lower fitting.
^ Position the tube aside.





17. Disconnect the main vacuum harness.





18. Disconnect and remove the Positive Crankcase Ventilation (PCV) hose.





19. Remove the four bolts and remove the throttle body adapter.
^ Inspect the throttle body and adapter for damage.





20. Remove the power steering reservoir upper mounting bracket.
21. Disconnect and remove the eight ignition coils.





22. Disconnect the eight fuel injectors.





23. Rotate the belt tensioner clockwise and detach the drive belt from the alternator pulley.





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





25. Remove the generator lower mounting bolts and position the generator aside.





26. Disconnect the heater hose.
27. Relieve the fuel system pressure.
28. Disconnect the fuel tubes.





29. Remove the bolts, water thermostat housing and thermostat.6 Discard the O-ring seal.





30. Remove the nine bolts.





31. 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. Connect the heater hose.





8. Position the generator and install the lower mounting bolts.





9. Install the generator upper mounting bracket.





10. Rotate the belt tensioner clockwise and install the drive belt. Refer to the decal on the radiator upper air deflector for belt routing.





11. Connect the eight fuel injector electrical connectors.
12. Install and connect eight ignition coils.





13. Install the power steering reservoir upper mounting bracket.





14. Install the throttle body adapter and the four bolts.





15. Install the PCV hose.





16. Install the exhaust manifold to EGR valve tube. 0 Hand-tighten the fittings.
^ Tighten the upper fitting.
^ Tighten the lower fitting.
17. Connect the fuel tubes.





18. Connect the brake booster vacuum tube and bracket and install the nut.





19. Roughly position the vacuum harness and connect the evaporative emission canister purge valve vacuum hose.





20. Connect the differential pressure feedback EGR system electrical connector.





21. Connect the fuel pressure regulator vacuum hose.





22. Connect the evaporative emission canister purge valve hose and the EGR valve vacuum hose.





23. Connect the TP sensor and IAC electrical , , connectors.





24. Connect the EGR vacuum regulator solenoid connections.





25. Install the IAC fresh air hose.





26. Connect the main vacuum harness.





27. Install the accelerator cable bracket and the bolts.





28. Connect the throttle body cam.
1 Connect the accelerator cable.
2 Connect the speed control actuator cable.
3 Install the throttle return spring.





29. Connect the upper radiator hose and position the clamp.
30. Install the air cleaner outlet pipe.
31. Connect the battery ground, cable.
32. Fill and bleed the engine cooling system.