Intake Manifold Replacement

REMOVAL PROCEDURE





1. Disconnect the battery ground (negative) cable.
2. Carefully disconnect the throttle body air inlet duct from the throttle body.
3. Partially drain the engine coolant from the cooling system.
4. Remove the fuel injector sight shield.
5. Disconnect the accelerator and cruise control cables from the throttle body and accelerator cable bracket.
6. Disconnect the throttle body coolant hoses from the throttle body.





7. Disconnect the fuel lines from the throttle body. Refer to Fuel Pressure Relief Procedure and Quick Connect Fitting(s) Service or Quick Connect Fitting(s) Service (Service) in Powertrain Management.





8. Disconnect the fuel vapor line from the EVAP canister purge solenoid.





9. Disconnect the brake booster vacuum hose from the brake booster.





10. Disconnect the A/C vacuum hose from the intake manifold.
11. Disconnect the surge tank inlet pipe retainer from the fuel injector rail.
12. Disconnect the fuel injector wiring harness connectors.
13. Disconnect the engine wiring harness connectors from the following components:
^ Throttle Position (TP) sensor
^ Idle Air Control (IAC) valve
^ EVAP canister purge solenoid
^ Manifold Absolute Pressure (MAP) sensor
14. Remove the engine wiring harness channel bolts from the camshaft covers.
15. Remove and set aside the engine wiring harness and channel.





16. Disconnect the fuel pressure regulator vacuum tube (1) from the regulator (2) and the throttle body (3).





17. Disconnect and remove the PCV valve and both feed tubes (1, 2) from the camshaft covers and intake manifold.





18. Remove the EGR valve outlet pipe retaining bolts from the intake manifold (1) and the water crossover (2).
19. Remove the EGR valve outlet pipe (3).





20. Disconnect the four fuel rail snap-lock retainers by pushing toward the camshaft covers and lifting.
21. Remove the fuel rail (1) and fuel injectors (2) as an assembly and store in a clean, secure location away from any heat sources.





22. Remove the throttle body heater hose insulator (2).





23. Remove the intake manifold bolts.





24. Disconnect the throttle body coolant hose from the water crossover feed tube (1).





25. Remove the intake manifold.

Important: If you are NOT replacing the intake manifold skip the following steps.

26. If necessary, disassemble the intake manifold.
27. Clean and inspect the intake manifold.

INSTALLATION PROCEDURE

Important: If you did NOT replace the intake manifold skip the intake manifold assembly.





1. If necessary, assemble the intake manifold.
2. Install the intake manifold.





3. Connect the throttle body heater hose to the water crossover feed tube (1).
4. Install the hose clamp.





Notice: Refer to Fastener Notice in Service Precautions.

Important: Tighten the intake manifold bolts in circular pattern starting from the center and moving outward.

5. Install the intake manifold bolts.
^ Tighten the intake manifold bolts to 7 Nm (62 inch lbs.).





6. Install the throttle body heater hose insulator (2).





7. Inspect the fuel injector O-rings (2) for misalignment or damage. Replace the O-rings if necessary.
8. Install the fuel rail (1) and fuel injectors (2) by aligning the fuel injectors with their respective ports and pressing the for fuel rail snap-lock connectors into the intake manifold until they lock in place. DO NOT apply excessive pressure to the fuel rail in place. The need for excessive pressure may be caused by misalignment of a fuel injector and could cause damage to the seal or intake manifold.





9. Install a new EGR outlet pipe (3).
10. Install the EGR outlet pipe to intake manifold bolt (1).
^ Tighten the EGR outlet pipe to intake manifold bolt to 10 Nm (89 inch lbs.).
11. Install the EGR outlet pipe to water crossover bolt (2).
^ Tighten the EGR outlet pipe to water crossover bolt to 24 Nm (118 ft. lbs.).





12. Install the PCV valve and connect both feed tubes (1, 2) to the camshaft covers and intake manifold.





13. Connect the brake booster vacuum hose to the brake booster.





14. Connect the fuel pressure regulator vacuum tube (1) to the regulator (2) and the throttle body (3).





15. Connect the A/C vacuum hose to the intake manifold.
16. Install the engine wiring harness and channel.
17. Install the engine wiring harness channel bolts to the camshaft covers.
^ Tighten the engine wiring harness channel bolts to 10 Nm (89 inch lbs.).
18. Connect the surge tank inlet pipe retainer to the fuel injector rail.
19. Connect the engine wiring harness connectors to the following components:
^ Throttle position (TP) sensor
^ Idle air control (IAC) valve
^ EVAP canister purge solenoid
^ Manifold absolute pressure (MAP) sensor
20. Connect the fuel injector wiring harness connectors.
21. Connect the throttle body coolant hoses to the throttle body.
22. Connect the accelerator and cruise control cables to the throttle body and accelerator cable bracket.





23. Connect the fuel lines to the throttle body.





24. Connect the fuel vapor line to the EVAP canister purge solenoid.





25. Install the fuel injector sight shield (3).
26. Carefully connect the throttle body air inlet duct to the throttle body.
27. Fill the cooling system with engine coolant.
28. Connect the battery ground (negative) cable.