Intake Manifold Lift and Support Procedure

TOOLS REQUIRED
^ J 37088 Fuel Line Disconnect Set
^ J 44095 Fuel Pressure Adapter Fitting
^ J 45482 Debris Screen
^ SA9127E Gauge Bar Set

REMOVAL

CAUTION: DO NOT ALLOW SMOKING DURING THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL OR EVAP SYSTEM IS TAKING PLACE. ANYTIME WORK IS BEING DONE ON THE FUEL SYSTEM, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.

NOTE: When servicing intake manifold, do not use power tools. Damage to threads or manifold may result.

Important: This procedure can be used to access many components under the intake manifold without having to completely remove the manifold assembly.




1. Disconnect negative battery cable.

CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING TO COLLECT FUEL. PLACE CLOTH IN AN APPROVED CONTAINER.

2. Relieve fuel system pressure. Refer to "Fuel System Pressure Relief" procedure in the Fuel System.
3. Disconnect Gauge Bar Set SA9127E (or equivalent) and Fuel Pressure Adapter Fitting J 44095 (or equivalent) after pressure has been relieved.
4. Disconnect fuel transfer line at quick connect from fuel line using Fuel Line Disconnect Set J 37088 (or equivalent) (blue tool).




5. Loosen clamp at air cleaner assembly and throttle body assembly
6. Remove attachment bolts from outlet resonator/duct assembly to support bracket.
7. Remove outlet resonator/duct assembly.




8. Remove outlet resonator duct assembly bracket to manifold nuts.
9. Remove outlet resonator duct assembly bracket.
10. Disconnect brake booster hose at brake booster.
11. Disconnect intake manifold runner control solenoid and fuel injector connector (solenoid does not require removal).
12. Remove intake port dust cover.




13. Remove 5 upper manifold bolts (1/4 in. drive T-30 with a 6 in. extension can be used to gain access).




14. Remove lower intake bolt under throttle body assembly (throttle body assembly removal is not required).




15. Disconnect purge solenoid and hose from manifold and position away from manifold.




16. Remove rear electrical harness bolts to manifold.
17. Disconnect throttle body electrical connector.
18. Position harness away from manifold.




19. Disconnect small PCV hose at throttle body.

NOTE: Care must be taken while lifting and supporting intake manifold assembly.

Important: To gain access to all components under the intake manifold the manifold can be loosened and tilted upward.




20. Lift intake manifold from cylinder head. (Manifold will not be completely removed.)
21. Tie or support intake manifold when desired position is achieved.
22. Install Debris Screen J 45482 onto spacer plate to prevent debris from entering into cylinder head/cylinder.

INSTALLATION




1. Remove debris screen from spacer.
2. Verify correct hose routing (PCV hose to ventilation chamber).
3. Remove tie up or support from intake manifold assembly. Position intake manifold to spacer plate and cylinder heads.




4. Connect small PCV hose at throttle body.




5. Reposition electrical harness onto intake manifold assembly.
6. Connect and throttle body electrical connector.
7. Install rear electrical harness bolts to manifold.

Torque:
Rear Electrical harness-to-Manifold Bolts - L81: 7.5 N.m (66 in. lbs.)




8. Install purge line and connect purge valve onto manifold.
9. Connect purge nut at rear of intake manifold.




10. Install 5 upper manifold bolts (1/4 in. drive T-30 with a 6 in. extension can be used to gain access to bolts).

Torque:
Upper Intake Manifold-to-Spacer Bolts - L81: 7.5 N.m (66 in. lbs.)




11. Install lower intake manifold bolt under throttle body assembly.

Torque:
Lower Intake Manifold-to-Spacer Bolt - L81: 7.5 N.m (66 in. lbs.)




12. Install intake port dust cover plate.
13. Connect electrical connector to intake runner control solenoid.
14. Install outlet resonator duct bracket assembly into position.
15. Install outlet resonator bracket to intake manifold nuts.

Torque:
Outlet Resonator Duct Assembly Bracket-to-Intake Manifold Nuts - L81: 5 N.m (44 in. lbs.)




16. Install outlet resonator duct assembly into position.
17. Tighten clamp at throttle body assembly
18. Position outlet resonator duct assembly to support bracket and install bolts.

Torque:
Outlet Resonator/Duct Assembly-to-Support Bracket Bolts - L81: 10 N.m (89 in. lbs.)

19. Tighten clamp at air cleaner assembly.
20. Connect negative battery cable.

Torque:
Battery Terminal Bolt: 17 N.m (13 ft. lbs.)