Removal and Replacement

Intake Manifold













Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Disconnect the fuel supply spring lock coupling from the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.

2. Drain the cooling system. For additional information, refer to Cooling System &/or Engine Block Heater.

3. Remove the generator. For additional information, refer to Charging System.

4. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.

5. Disconnect the upper radiator hose from the thermostat housing.

6. Disconnect the heater coolant hose and PCV coolant hose from the engine coolant crossover assembly.

7. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.

8. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.

9. Disconnect the 10 fuel injector electrical connectors.

10. Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.

11. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.

12. Disconnect the quick connect coupling and remove the crankcase ventilation tube. For additional information, refer to Fuel Delivery and Air Induction.

13. Disconnect the wiring harness and vacuum harness retainers from the rear of the intake manifold.

14. Disconnect the engine vacuum hose connections from the rear of the intake manifold and position aside.

15. Disconnect the 2 heated PCV coolant hoses from the intake manifold.

16. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.

17. Disconnect the engine wiring harness position retainers from the intake manifold.

18. Remove the 12 intake manifold bolts.

19. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the 3 bolts, the engine coolant crossover manifold assembly and discard the 2 gaskets.

- Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

20. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the intake manifold and discard the 10 gaskets.

- Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Installation

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.

Using 10 new intake manifold gaskets, position the intake manifold.

2. Using 2 new gaskets, position the engine coolant crossover manifold assembly and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).

3. Install the intake manifold bolts and tighten in 2 stages in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 10 Nm (89 lb-in).





4. Connect the TP sensor and ETC electrical connectors.

5. Connect the engine wiring harness position retainers to the intake manifold.

6. Connect the engine vacuum hose connections to the rear of the intake manifold.

7. Connect the wiring harness and vacuum harness retainers to the rear of the intake manifold.

8. Connect the PCV tube quick connect coupling to the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.

9. Position the EVAP tube and connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.

10. Connect the 2 heated PCV coolant hoses to the intake manifold.

11. Connect the 10 fuel injector electrical connectors.

12. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.

13. Connect the IMRC actuator electrical connector.

14. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.

15. Connect the heater coolant hose to the coolant crossover assembly.

16. Connect the heated PCV coolant hose to the coolant crossover assembly.

17. Connect the upper radiator hose to the thermostat housing.

18. Position the crankcase ventilation tube and connect the quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.

19. Install the generator. For additional information, refer to Charging System.

20. Install the ACL outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.

21. Fill and bleed the engine cooling system. For additional information, refer to Cooling System &/or Engine Block Heater.