Intake Manifold

Intake Manifold

Special Tools And Equipment:

Special Tool(s)

Material:

Material














Removal

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

1. Drain the cooling system.
2. Release the fuel system pressure.
3. Remove the generator.
4. Remove the air cleaner.
5. Disconnect the upper radiator hose from the thermostat housing.
6. Disconnect the heater coolant hose from the coolant bypass tube.
7. Disconnect the evaporative emissions system (EVAP) tube from the intake manifold.
8. Remove the positive crankcase ventilation (PCV) tube.
9. Disconnect the fuel supply spring lock coupling from the fuel rail.
10. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
11. Disconnect the ~ fuel injector electrical connectors.
12. Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors.





13. Disconnect the heated PCV intake fitting electrical connector.
14. Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
15. Remove the 10 intake manifold bolts

16. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the 3 bolts, the coolant bypass tube and discard the gaskets.
^ Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.
17. Disconnect the charge motion control valve (CMCV) electrical connector.
18. Disconnect the manifold vacuum tube from the valve cover stud and the support bracket.





19. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.





20. Disconnect the LH and RH knock sensor (KS) electrical connectors.
21. Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud.

22. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the intake manifold and discard the gaskets.
^ Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Installation

1. NOTE: Electrical and vacuum harnesses must not restrict movement of the charge motion control valve (CMCV) control rods at rear of the intake manifold. Use extreme care on installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.

Using new intake manifold gaskets, position the intake manifold.
2. Using new gaskets, position the coolant crossover and install the 3 bolts
^ Tighten to 10 Nm (89 inch lbs.).





3. Install the intake manifold bolts and tighten in 2 stages in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).
4. Connect the engine wiring harness retainer to the CMCV stud and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
5. Connect the CMCV electrical connector.





6. Connect the cylinder head temperature (CHT) sensor jumper harness electrical connector.





7. Connect the LH and RH knock sensor (KS) electrical connectors.
8. Connect the manifold vacuum tube to the support bracket and the valve cover stud and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
9. Connect the brake booster vacuum hose to the intake manifold vacuum tube.





10. Connect the heated positive crankcase ventilation (PCV) intake fitting electrical connector.
11. Connect the throttle position (TP) sensor and electronic acceleration control electrical connectors.
12. Connect the 8 fuel injector electrical connectors.
13. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
14. Connect the fuel supply spring lock coupling from the fuel rail.
15. Install the PCV tube.
16. Connect the evaporative emissions system (EVAP) tube to the intake manifold.
17. Connect the heater coolant hose to the coolant bypass.
18. Connect the upper radiator hose to the thermostat housing.
19. Install the generator.
20. Install the air cleaner.
21. Fill and bleed the engine cooling system.