Intake Air Plenum: Service and Repair

Fuel Pump Fuse Location:

REMOVAL
1. Release fuel system pressure.
^ Remove the fuel pump fuse.
^ Start and run the engine until it dies.
2. Remove the negative battery cable.

Removing Air Intake Duct:

3. Remove the intake air duct.
4. Drain all coolant from the radiator.
^ Drain cock is located on the bottom corner, passenger's side.
5. Remove or disconnect the following:
^ All harness connectors and tubing
^ EGR Valve

Intake Collector Removal And Replacement:

6. Remove the intake collector.
^ Loosen all collector bolts a little at a time in a crossing pattern.

INSTALLATION
1. Clean all mating surfaces thoroughly.
^ Manifold to collector seals can be re-used if there is no damage. If there is any doubt, replace the seals.
2. Place intake collector onto the manifolds and tighten bolts by hand.
3. Torque intake collector bolts in a crossing pattern to:
^ 12 - 15 Nm (9 - 11 ft. lbs.)
4. Re-install:
^ All harnesses and tubing
^ EGR Valve
^ Intake air duct
5. Slowly fill the radiator with coolant.
6. Re-install fuel pump fuse and connect the battery cable.
7. Start engine and check for leaks and verify driveability.