Intake Manifold Replacement

Intake Manifold Replacement

Removal Procedure

Important: The intake manifold, throttle body, fuel injection rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

1. Remove the engine sight covers.
2. Drain the cooling system. Refer to Draining and Filling Cooling System (GE 47716) Draining and Filling Cooling System (Static Fill).




3. Remove the wiring harness clips from the fuel rail and position the harness aside.
4. Disconnect the electrical connector (1) for the fuel injectors.
5. Disconnect the electrical connectors (3) from the throttle body.
6. Disconnect the fuel feed for the fuel injectors.




7. Remove the vacuum hose from the brake booster.
8. Disconnect the electrical connector from the manifold absolute pressure (MAP) sensor.
9. Remove the MAP sensor.
10. Remove the grommet from the sensor, as required.




11. Remove the evaporative emission (EVAP) clip (740), bolt (742), bracket (741), valve (730), and tubes (729, 735).




12. Remove the intake manifold bolts (512) and fuel rail stop bracket (712).
13. Remove the intake manifold (500).




14. Remove the intake manifold gaskets (514).
15. Discard the intake manifold gaskets.

Installation Procedure





Important:
* The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, install the intake manifold as a complete assembly.

* DO NOT use the intake manifold gaskets again. Install NEW intake manifold-to-cylinder head gaskets.

Install NEW intake manifold-to-cylinder head gaskets (514).





Important: Have both the left and right rear most intake manifold bolts installed along with the fuel rail protection end brackets prior to installing the intake manifold on the engine.

1. Install the intake manifold (500).
2. Apply a 5 mm (0.20 in) band of threadlocker to the threads of the intake manifold bolts (512). Refer to Sealers, Adhesives, and Lubricants for the correct part number.




3. Install the fuel rail stop bracket (712).

Notice: Refer to Fastener Notice.

4. Install the intake manifold bolts (512).

* First Pass: Tighten the intake manifold bolts in sequence to 5 N.m (44 lb in).
* Final Pass: Tighten the intake manifold bolts in sequence to 10 N.m (89 lb in).




5. Lubricate the MAP sensor grommet (715) with clean engine oil.
6. Install the MAP sensor (714) and grommet (715).




7. Install the EVAP valve (730), bracket (741), and bolt (742).

Tighten the bolt to 50 N.m (37 lb ft).

8. Install the EVAP tubes (729, 735).
9. Install the fuel rail.
10. Reconnect the electrical connector for the MAP sensor.




11. Install the vacuum hose for the brake booster.




12. Reconnect the electrical connectors (3) throttle body.
13. Reconnect the electrical connector (1) for the fuel injectors.
14. Install the wiring harness clips to the fuel rail and reconnect the wiring harness.
15. Refill the cooling system. Refer to Draining and Filling Cooling System (GE 47716) Draining and Filling Cooling System (Static Fill).
16. Install the engine sight covers.