Intake Air Plenum: Service and Repair

Air Plenum And Fuel Rail Removal:

REMOVAL
1. Disconnect negative battery terminal.
2. Remove vacuum lines, noting positions of hoses.
3. Remove Exhaust Gas Recirculation (EGR) to plenum nuts.
4. Remove the two throttle body attaching bolts, throttle body and gasket. Discard gasket.
5. Remove throttle cable bracket bolts.
6. Remove ignition wire plastic shield bolts.
7. Remove plenum bolts.
8. Remove plenum and gaskets. Discard gaskets.

CAUTION: Use care in cleaning old gasket material from machined aluminum surfaces. Sharp tools may damage sealing surfaces.

INSTALLATION
1. Install new plenum gaskets.
2. Install plenum and plenum bolts and torque to 21 Nm (16 lb ft).
3. Install ignition wire plastic shield bolts.
4. Install throttle body bolts and torque to 25 Nm (18 lb ft).
5. Install EGR to plenum nuts.
6. Install throttle cable bracket bolts.
7. Connect vacuum lines.
8. Connect negative battery terminal

NOTE: With the engine "OFF," depress the throttle pedal and release to check that it is free.

9. Before starting engine do the Idle Learn Procedure
- Install Tech 1 Scan tool.
- Ignition ON, engine OFF.
- Select Idle Air Control (IAC) SYSTEM, then IDLE LEARN in the MISC TEST mode.
- Proceed with idle learn as directed.
This procedure allows the Engine Control Module (ECM) memory to be updated with the correct IAC valve pintle position for the vehicle and provides for a stable idle speed.