Intake Plenum Replacement

Intake Plenum Replacement

Removal Procedure

1. Remove the intake plenum air inlet hose clamps and hoses from the throttle body.





2. Remove the brake booster vacuum fitting (2) from the intake plenum.
3. Remove the wiring harness channel bolts (1) and position the channel out of the way.





4. Disconnect the electrical connector (1) and vacuum hose (2) from the switch-over valve on the back of the plenum.
5. Disconnect the throttle body control electrical connector.





6. Remove the throttle body bolts.





7. Remove the throttle body from the plenum.





8. Remove the crankcase vent tube adapter cover by gently prying up on the side.
9. Remove the crankcase vent tube adapter screws from the plenum and position the adapter out of the way.
10. Unclip the heater hose retaining clamp from the bracket on the right side of the plenum and position the heater hoses out of the way.





11. Remove the intake plenum bolt caps.
12. Remove the intake plenum bolts.
13. Remove the intake plenum.

Notice: Mask off the ports to the intake manifold after removing the plenum O-rings. Severe damage may result if foreign objects enter the engine.

14. Remove the intake plenum O-rings.

Installation Procedure





1. Remove the masking from the intake plenum ports and ensure the sealing surfaces are clean and dry.
2. Lightly coat the intake plenum O-rings with engine oil and install in the intake manifold.
3. Install the intake plenum to the intake manifold. Ensure the alignment pins are properly seated.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the intake plenum bolts.
Tighten the intake plenum bolts to 8 Nm (71 inch lbs.).
5. Install the intake plenum bolt caps.
6. Install the heater hoses into the retaining clamp on the right side of the plenum and snap the retainer closed.





7. Inspect and lightly lubricate with engine oil the seals on the crankcase vent tube adapter.
8. Install the crankcase vent tube adapter and screws.
Tighten the crankcase vent tube adapter screws to 8 Nm (71 inch lbs.).
9. Install the crankcase vent tube adapter cover and snap into place.





10. Inspect the throttle body O-ring seals and replace if necessary.
11. Install the throttle body.
12. Install the throttle body bolts.
Tighten the throttle body bolts to 12 Nm (106 inch lbs.).





13. Connect the throttle body control electrical connector.





14. Connect the electrical connector (1) and vacuum hose (2) to the switch-over valve on the back of the plenum.





15. Install the wiring harness channel and bolts (1).
Tighten the wiring harness channel bolts to 8 Nm (71 inch lbs.).
16. Install the brake booster vacuum fitting (2) to the intake plenum.
Tighten the brake booster vacuum fitting until fully seated and not stripped.
17. Install the intake plenum air inlet hoses to the throttle body and tighten the clamps.