Intake Air Plenum: Service and Repair

Removing Plenum And Fuel Rail:

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Vacuum lines, noting positions of hoses.
3. Exhaust Gas Recirculation (EGR) to plenum nuts.
4. Throttle body.
^ Refer to Throttle Body Assembly.
5. Ignition coil assembly front bolts.
6. Braces to alternator.
7. Manifold Absolute Pressure (MAP) sensor and bracket.
8. Plenum bolts.
9. Plenum and gaskets. Discard gaskets.

NOTICE:Use care in cleaning old gasket material from machined aluminum surfaces as sharp tools may damage sealing surfaces.

Clean
^ Gasket sealing surfaces.

INSTALL OR CONNECT
1. New plenum gaskets.

CAUTION: Be sure to route MAP sensor electrical connector to the outside of plenum gasket.


2. Plenum.
3. Plenum bolts.

Tighten
Plenum bolts to 25 Nm (18 lb. ft.).

4. MAP sensor.
5. Braces to alternator.
6. Ignition coil assembly front bolts.
7. EGR to plenum bolts.
8. Vacuum lines as noted during disassembly.
9. Throttle body.
^ Refer to Throttle Body Assembly.
10. Negative battery cable.

INSPECT
^ With the engine "OFF" check to see that the accelerator cable is free:
- Depress pedal to the floor and release.