Intake Air Plenum: Service and Repair

Removing the fuel rail assembly from the engine requires removing the top portion of the tuned intake manifold, called the "plenum."

Air Plenum And Fuel Rail Removal:

REMOVE OR DISCONNECT:

1. Negative battery terminal.
2. Vacuum lines, noting positions of hoses.
3. EGR to plenum nuts.
4. Two throttle body attaching bolts, throttle body and gasket. Discard gasket.
5. Throttle cable bracket bolts.
6. Ignition wire plastic shield bolts.
7. Plenum bolts.
8. Plenum and gaskets. Discard gaskets.
9. Clean the gasket sealing surfaces.

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

INSTALL OR CONNECT:

1. New plenum gaskets.
2. Plenum.
3, Plenum bolts. Tighten plenum bolts to 10 Nm (88 in lb).
4. Ignition wire plastic shield bolts.
5. Throttle body with new gasket.
6. Throttle body bolts. Tighten throttle body bolts to 25 Nm (18 ft lb).
7. EGR to plenum nuts.
8. Throttle cable bracket bolts.
9. Vacuum lines.
10. Negative battery terminal.
11. With the engine "OFF," check to see that the accelerator pedal is free: Depress pedal to the floor and release.
12. Perform the "Idle Learn Procedure." The ECM will need to relearn the IAC valve pintle position following battery reconnect.

IDLE LEARN PROCEDURE: Any time the battery is disconnected, the programmed position of the IAC valve pintle is lost, and replaced with a default value. To return the IAC valve pintle to the correct position, perform the following procedure:

1. After restoring battery power, connect the Tech 1 "SCAN" tool.
2. Select "IAC SYSTEM," then select "IDLE LEARN" in the "MISC TEST" mode.
3. Proceed with idle learn as directed.
^ This procedure allows the ECM memory to be updated with the correct IAC valve pintle position, for the vehicle, and provide a stable idle speed.