Overhaul

Intake Manifold Assembly





Throttle Body (TB) and TB (Throttle Body) Spacer










Fuel Rail and Fuel Injector









Disassembly

1. Disconnect the Evaporative Emission (EVAP) canister purge valve-to-intake manifold quick connect coupling.

2. Remove the bolt and the EVAP (Evaporative Emission) canister purge valve.

3. Remove the 4 bolts and the Throttle Body (TB).
- Discard the TB (Throttle Body) gasket.

4. Remove the 6 bolts and the TB (Throttle Body) spacer.

5. Remove the Intake Manifold Runner Control (IMRC) actuator rod C-clip.

6. Remove the 3 bolts and the IMRC (Intake Manifold Runner Control) actuator.

7. NOTE: The fuel rail and fuel injectors are removed as an assembly.
Remove the 6 bolts and the fuel rail assembly.

8. Remove the 10 fuel injector-to-fuel rail locking clips and separate the fuel injectors from the fuel rail.
- Discard the 2 O-ring seals from each fuel injector.


Assembly

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.
Install 2 new O-ring seals on each of the fuel injectors.

2. Assemble the fuel injectors onto the fuel rail and install the locking clips.

3. Install the fuel rail and fuel injector assembly onto the intake manifold.

4. Install the 6 fuel rail bolts.
- Tighten to 10 Nm (89 lb-in).

5. Position the TB (Throttle Body) spacer.

6. Install the 2 upper TB (Throttle Body) spacer bolts in 2 stages:
- Stage 1: Tighten to 7 Nm (62 lb-in).

- Stage 2: Tighten an additional 90 degrees.

7. Install the 4 lower TB (Throttle Body) spacer bolts in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 90 degrees.

8. Install a new gasket and the TB (Throttle Body). Tighten the 4 bolts in 2 stages:
- Stage 1: Tighten to 9 Nm (80 lb-in).

- Stage 2: Tighten an additional 90 degrees.

9. Install the EVAP (Evaporative Emission) canister purge valve and bolt.
- Tighten to 10 Nm (89 lb-in).


10. Connect the EVAP (Evaporative Emission) canister purge valve-to-intake manifold quick connect coupling.

11. Position the IMRC (Intake Manifold Runner Control) actuator and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).


12. Install the IMRC (Intake Manifold Runner Control) rod C-clip.