Intake Manifold Assembly - Disassembly And Assembly

Intake Manifold Assembly





Throttle Body (TB) and TB Spacer









Fuel Rail and Fuel Injector









Disassembly

1. Remove the 4 bolts and the Throttle Body (TB).
- Discard the TB gasket.

2. Remove the 6 bolts and the TB spacer.

3. Remove the Intake Manifold Runner Control (IMRC) actuator rod C-clip.

4. Remove the 3 bolts and the IMRC actuator.

5. NOTE: The fuel rail and fuel injectors are removed as an assembly.

Remove the 6 bolts and the fuel rail assembly.

6. Remove the 10 fuel injector-to-fuel rail locking clips and separate the fuel injectors from the fuel rail.
- Discard the 2 O-ring seals from each fuel injector.

Assembly

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.

Install 2 new O-ring seals on each of the fuel injectors.

2. Assemble the fuel injectors onto the fuel rail and install the locking clips.

3. Install the fuel rail and fuel injector assembly onto the intake manifold.

4. Install the 6 fuel rail bolts.
- Tighten to 10 Nm (89 lb-in).

5. Position the TB spacer.

6. Install the 2 upper TB spacer bolts in 2 stages:
- Stage 1: Tighten to 7 Nm (62 lb-in).

- Stage 2: Tighten an additional 90 degrees.

7. Install the 4 lower TB spacer bolts in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 90 degrees.

8. Install a new gasket and the TB. Tighten the 4 bolts in 2 stages:
- Stage 1: Tighten to 9 Nm (80 lb-in).

- Stage 2: Tighten an additional 90 degrees.

9. Position the IMRC actuator and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).

10. Install the IMRC rod C-clip.