Procedures

Intake Manifold

Material:

Removal

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can 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. Do not work on any fuel system component until fuel system pressure has been relieved. Failure to follow these instructions may result in personal injury.

1. Remove the engine cover.
2. Disconnect the fuel supply hose spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
3. Disconnect the battery ground cable. For additional information, refer to Battery.
4. Drain the cooling system. For additional information, refer to Cooling System.
5. Remove the air cleaner and the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
6. Remove the generator. For additional information, refer to Alternator.
7. Compress and slide the hose clamp and disconnect the coolant hose.





8. NOTE: The red clip must be pulled out before disconnecting the electrical connector.

Disconnect the electronic throttle body (TB) electrical connector.





9. NOTE: The red clip must be pulled out before disconnecting the electrical connector.

Disconnect the throttle position (TP) sensor electrical connector.





10. Disconnect the positive crankcase ventilation (PCV) tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





11. Disconnect the 2 coolant hoses and the vacuum tube connector.





12. Disconnect the brake booster vacuum hose and the evaporative emission (EVAP) hose quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





13. Remove the 4 bolts and the TB and adapter as an assembly.
^ Discard the TB adapter gasket.





14. Disconnect the heater coolant hose.





15. Disconnect the vacuum connector.





16. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
17. Disconnect the 10 fuel injector electrical connectors.





18. Disconnect the 10 ignition coil electrical connectors.





19. Remove the nut for the transmission fluid indicator and tube.





20. Remove the transmission fluid level indicator tube bracket retaining nut and position the tube aside.





21. Remove the stud bolts and position the RH fuel charge wiring harness aside.





22. Remove the bolts and position the LH fuel charge wiring harness aside.





23. Remove the 10 bolts and the 10 ignition coils.
24. Disconnect the pushpin retainer from the intake manifold bracket.





25. Remove the 2 bolts, thermostat housing and thermostat.
^ Discard the O-ring seal.
26. Remove the 11 bolts, the intake manifold and the intake manifold gaskets.
^ Discard the intake manifold gaskets.

Installation

1. 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.

Clean the mating surfaces of the cylinder head and the intake manifold with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
2. Position new intake manifold gaskets and the intake manifold, and loosely install the 11 bolts.
3. Using a new O-ring seal, install the thermostat.

4. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.

Position the thermostat housing and loosely install the 2 bolts.

5. Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 2 Nm (18 inch lbs).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs).





6. Connect the pushpin retainer to the intake manifold bracket.





7. Position the 10 ignition coils and install the 10 bolts.
^ Tighten to 6 Nm (53 inch lbs).
8. Position back the LH fuel charging wiring harness and install the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs).





9. Position back the RH fuel charging wiring harness and install the stud bolts.
^ Tighten to 10 Nm (89 inch lbs).





10. Position back the transmission fluid level indicator tube and install the retaining nut.
^ Tighten to 10 Nm (89 inch lbs).





11. Install the transmission fluid indicator and tube nut.
^ Tighten to 28 Nm (21 ft. lbs).





12. Connect the 10 ignition coil electrical connectors.





13. Connect the 10 fuel injector electrical connectors.





14. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
15. Connect the vacuum connector.





16. Connect the heater coolant hose.





17. Install a new TB adapter gasket and the TB and adapter as an assembly. Tighten the 4 bolts in 2 stages.
^ Stage 1: Tighten the bolts to 9 Nm (80 inch lbs).
^ Stage 2: Tighten the bolts an additional 90 degrees.





18. Connect the brake booster vacuum hose and the EVAP hose quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





19. Connect the 2 coolant hoses and the vacuum connector.





20. Connect the PCV tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





21. Connect the TP sensor electrical connector.
^ Push in the red clip.





22. Connect the electronic TB electrical connector.
^ Push in the red clip.





23. Install the upper radiator hose.





24. Install the generator. For additional information, refer to Alternator.
25. Install the air cleaner assembly and tubes. For additional information, refer to Fuel Delivery and Air Induction.
26. Connect the fuel hose spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
27. Connect the battery ground cable. For additional information, refer to Battery.
28. Fill the cooling system. For additional information, refer to Cooling System.
29. Install the engine cover.