A-8 ~ Intake Manifold Diagnostic Plate Installation

Circuit Description
Due to the inaccessibility of the Fuel Rail, Fuel Injectors, Fuel Rail pressure test fitting and the Knock Sensor as well as the Engine Coolant Sensor, it will be necessary to install the Intake Manifold Diagnostic Plate to be able to run the engine with the plenum assembly removed.

Diagnostic Aids
- The ground stud is provided for the Engine Control Module ground so as to not create any additional driveability problems while testing.
- Bolt hole "D" is to mount the Electronic Ignition assembly to the Manifold Plate.
- It is important to clear any malfunction Diagnostic Trouble Codes after the Manifold Plate is removed. Re-test the vehicle to insure no malfunction Diagnostic Trouble Codes have reset.
- The Exhaust Gas Recirculation block plate is used to cover the opening in the Exhaust Manifold where the Exhaust Gas Recirculation exhaust tube originally was connected.

Installation Procedure

NOTE: The Intake Manifold Diagnostic Plate is used to allow the engine to be run with the common chamber assemble removed. It is not intended to allow a technician to drive the vehicle with the Intake Manifold Plate Installed.

1. Relieve Fuel Pressure.
2. Disconnect negative battery cable.
3. Remove Intake Plenum assembly.
4. Install Manifold Diagnostic Plate with ground bolt to the rear of the engine. Install ground wires to bolt.
5. Use the six bolts to secure the Manifold Plate to the intake assembly.
6. Use bolt hole "D" to secure the Electronic Ignition unit to the Manifold Plate.
7. Install the Exhaust Gas Recirculation block plate at Exhaust Manifold.
8. Torque all fasteners to 8 - 12 lb.ft. (11 - 16 N.m).

CAUTION: Over-torquing the Intake Manifold Plate may damage the Intake Manifold Plates sealing surface. This will result in an "AIR LEAK" at the plate base gasket. This could result in a misdiagnosis of a driveability problem.

Starting Vehicle with Diagnostic Plate Installed
1. Set the plate slider to position "0".
2. Using a hand held vacuum pump, apply 12 - 15 inches (34 - 52 kPa) of vacuum to the Manifold Absolute Pressure Sensor and the Fuel Pressure Control Valve.
3. Crank engine and allow revolution per minute to stabilize. Run for 2 - 5 minutes.
4. Move slider bar to position "1" which will allow the engine to idle at 1000 to 1200 revolutions per minute. This allows any needed diagnostic tests to be performed.
5. Position "2" will cause the engine to stall. This is to allow the technician to stall the engine from outside of the vehicle.

Removal Procedure
1. Reverse the installation procedures.
2. Be sure to clear all codes and confirm vehicle is operating normally.