Intake Air Plenum: Service and Repair

Intake Plenum And Runners:

REMOVAL:

1. Disconnect the negative battery cable.
2. Partially drain the cooling system to allow the lower hose at the throttle body to be removed.
3. Remove the throttle, TV (transmission control), and cruise control cables.
4. Remove the cable retaining bracket.
5. Remove the throttle body to mass air flow sensor duct.
6. Disconnect the vacuum hoses.
7. Remove the lower coolant hose from the throttle body.
8. Remove the A.I.R. hoses from the air management valve.
9. Remove the 4 throttle body attaching bolts.
10. Remove the TPS and IAC valve electrical connectors.
11. Remove the injector electrical connectors, left/right electrical harness attaching nuts and harnesses.
12. Remove the power brake vacuum hose from the plenum.
13. Remove the left side runner to plenum bolts.
14. Remove the left side runner to manifold bolts.
15. Remove the PCV valve and hose.
16. Remove the right side runner to plenum bolts.
17. Remove the right side runner to manifold bolts.
18. Remove the EGR solenoid.
19. Remove the right side manifold to runner bolt.
20. Remove the plenum, right side runners and gaskets, discard gaskets.
21. Remove the left side manifold to runner bolt.
22. Remove the left side runners and gaskets, discard gaskets.
23. Clean the gasket sealing surfaces.

CAUTION: Use care in cleaning old gasket material from machined aluminum surfaces. Sharp tools may damage sealing surfaces.

INSTALLATION:

1. Install new gaskets on the runners and intake manifold.
2. Assemble left side runners and intake manifold bolts, finger tighten only.
3. Install the left side manifold to runner bolt and tighten to 34.0 Nm (25 lb.ft).
4. Assemble right side runners, and runner to manifold bolts and manifold to runner bolt, tighten finger tight only.
5. Install intake plenum and runner to plenum bolts.
6. Tighten bolts:
a. Runner to manifold bolts to 34.0 Nm (25.0 lb.ft). Start in the center and work outward.
b. Manifold to runner bolt to 34.0 Nm (25.0 lb.ft).
c. Runner to plenum bolts to 34.0 Nm (25.0 lb.ft). Start in the center and work outward.
7. Install the EGR solenoid.
8. Install the PCV valve and hose.
9. Install the power brake vacuum hose to the fitting on the plenum.
10. Install the left/right injector electrical harnesses, attaching nuts, and injector electrical connectors.
11. Attach the throttle body with 4 attaching bolts and tighten to 24.0 Nm (18 lb.ft).
12. Connect the A.I.R. hoses to the air management valve.
13. Connect the lower coolant hose to the throttle body.
14. Connect the vacuum hoses.
15. Install the throttle body to mass air flow sensor duct.
16. Install the throttle cable bracket.
17. Connect the throttle, T.V., and cruise control cables.
18. Refill the radiator.
19. Connect the negative battery cable.