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 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. Failure to follow these instructions may result in personal injury.

1. Drain the cooling system. For additional information, refer to Cooling System.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Disconnect the fuel supply hose spring lock coupling from the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.
4. Remove the generator. For additional information, refer to Alternator.
5. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
6. Disconnect the crankcase ventilation tube quick connect coupling from the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.
7. Disconnect the quick connect coupling and remove the evaporative emissions system (EVAP) hose from the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.
8. Disconnect the EVAP hose position retainer from the intake manifold.





9. Remove the 4 bolts and the air cleaner outlet pipe-to-TB adapter.
10. Disconnect the heater coolant hose from the coolant bypass tube.
11. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. For additional information, refer to Fuel Delivery and Air Induction.
12. Disconnect the 8 fuel injector electrical connectors.
13. Disconnect the 8 ignition coil electrical connectors.
14. Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors.
15. Disconnect the heated PCV intake fitting electrical connector.
16. Remove the intake manifold vacuum tube support bracket bolt and disconnect the intake manifold vacuum tube-to-intake manifold hose.
17. Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
18. Disconnect the intake manifold vacuum tube support retainer from the valve cover and position the intake manifold vacuum tube aside.
19. Remove the 10 intake manifold bolts.
20. Disconnect the charge motion control valve (CMCV) electrical connector.
21. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.





22. Disconnect the LH and RH knock sensor (KS) electrical connectors.





23. Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud.

24. 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.
^ Inspect and clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Installation

1. NOTE: Electrical and vacuum harnesses must not restrict movement of the 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. Connect the engine wiring harness retainer to the CMCV stud and install the nut.
^ Tighten to 10 Nm (89 inch lbs.)
3. Connect the CMCV electrical connector.
4. Connect the CHT sensor jumper harness electrical connector.





5. Connect the LH and RH KS electrical connectors.





6. 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.)





7. Install the intake manifold vacuum tube support bracket bolt and connect the intake manifold vacuum tube-to-intake manifold hose.
^ Tighten to 10 Nm (89 inch lbs.)
8. Connect the intake manifold vacuum tube support retainer to the valve cover and position the intake manifold vacuum tube aside.
9. Connect the brake booster vacuum hose to the intake manifold vacuum tube.
10. Connect the heated PCV intake fitting electrical connector.
11. Connect the TP sensor and electronic acceleration control electrical connectors.
12. Connect the 8 fuel injector electrical connectors.
13. Connect the 8 ignition coil electrical connectors.
14. Position the air cleaner outlet pipe-to-TB adapter and install the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.)
15. Connect the crankcase ventilation tube quick connect coupling to the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.
16. Position the EVAP hose and connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.
17. Connect the EVAP hose position retainer to the intake manifold.





18. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction.
19. Connect the heater coolant hose to the coolant bypass.
20. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.
21. Install the generator. For additional information, refer to Alternator.
22. Install the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
23. Connect the battery ground cable. For additional information, refer to Battery.
24. Fill and bleed the engine cooling system.