Removal and Replacement

Intake Manifold - 4.6L














Removal

WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Remove the engine cover.
2. Disconnect the fuel supply tube 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. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to Fuel Delivery and Air Induction.
6. Remove the throttle body (TB). For additional information, refer to Fuel Delivery and Air Induction.
7. Remove the 8 ignition coils. For additional information, refer to Ignition System.
8. Disconnect the upper radiator hose.
9. Disconnect the heater coolant hose.





10. Rotate the tensioner clockwise and remove the accessory drive belt from the generator pulley.





11. Disconnect the generator wiring harness retainer.





12. Remove the 3 bolts and the generator support bracket.
13. Remove the transmission fluid level indicator and tube bolt.
^ To install, tighten to 28 Nm (21 lb-ft).





14. Remove the nut and position the transmission fluid level indicator and tube aside.
^ To install, tighten to 10 Nm (89 lb-in).





15. Disconnect the vacuum harness connector.





16. Disconnect the crankcase vent tube quick connect coupling from the LH valve cover. For additional information, refer to Fuel Delivery and Air Induction.
17. Disconnect the EGR system module electrical connector.
18. Disconnect the EGR system module vacuum hose connector.
19. Disconnect the upper and lower fittings and remove the exhaust manifold-to-EGR system module tube.
20. Remove the 2 bolts and the EGR system module.
^ Discard the EGR system module gasket.
21. Disconnect the fuel pressure and temperature sensor electrical connector.
22. Disconnect the evaporative emissions (EVAP) system vapor tube quick connect coupling from the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.
23. Disconnect the PCV coolant hose from the TB adapter.
24. Disconnect the vacuum harness connector from the intake manifold.
25. Disconnect the 8 fuel injector electrical connectors.
26. Disconnect the wiring harness retainer from the rear of the RH cylinder head.





27. Disconnect the coolant hose from the heater outlet tube.





28. Remove the stud bolt and position the heater outlet tube aside.





29. Disconnect the 2 electrical connector position retainers from the support bracket and position the wiring harness onto the transmission.





30. Remove the 2 bolts, thermostat housing and thermostat.
^ Discard the O-ring seal.
31. Remove the 9 intake manifold bolts.
32. Remove the intake manifold and discard the intake manifold gaskets.
^ Inspect the intake manifold assembly for damage.

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 can cause leak paths. Use a plastic scraping tool to clean sealing surfaces.

Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
2. Position the new intake manifold gaskets, the intake manifold and loosely install the 9 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.

Install the thermostat housing and loosely install the 2 bolts.
5. Tighten the 11 bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 lb-in).
^ Stage 2: Tighten to 25 Nm (18 lb-ft).





6. Connect the 2 electrical connector position retainers to the support bracket.





7. Position the heater outlet tube and install the stud bolt.
^ Tighten to 25 Nm (18 lb-ft).





8. Connect the coolant hose to the heater outlet tube.





9. Connect the wiring harness retainer to the rear of the RH cylinder head.





10. Connect the 8 fuel injector electrical connectors.
11. Connect the PCV coolant hose to the TB adapter.
12. Connect the vacuum harness connector to the intake manifold.
13. Connect the EVAP system vapor tube quick connect coupling to the intake manifold.
14. Connect the fuel pressure and temperature sensor electrical connector.
15. Using a new gasket, position the EGR system module and install the 2 bolts.
^ Tighten to 25 Nm (18 lb-ft).
16. Position the exhaust manifold-to-EGR system module tube and connect the upper and lower fittings.
^ Tighten to 42 Nm (31 lb-ft).
17. Connect the EGR system module vacuum hose and electrical connector.
18. Connect the crankcase vent tube quick connect coupling to the LH valve cover.
19. Install the transmission fluid level indicator and tube bolt.
^ To install, tighten to 28 Nm (21 lb-ft).





20. Install the transmission fluid level indicator and tube nut.
^ Tighten to 10 Nm (89 lb-in).





21. Connect the vacuum harness connector.





22. Position the generator support bracket and install the 3 bolts.
23. Connect the generator wiring harness retainer.





24. Rotate the tensioner clockwise and install the accessory drive belt onto the generator pulley.





25. Connect the heater coolant hose.





26. Connect the upper radiator hose.
27. Connect the fuel supply tube spring lock coupling.
28. Install the 8 ignition coils.
^ Position the PCV tube and connect the quick connect couplings.
29. Install the throttle body (TB).
30. Install the engine cover.
31. Connect the battery ground cable. For additional information, refer to Battery.
32. Fill and bleed the engine cooling system.