Intake Air Plenum: Service and Repair

Removing Plenum And Fuel Rail:

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Drain coolant.
3. Air inlet duct.
4. Accelerator and cruise control cables at throttle body and accelerator control cable bracket.
5. Fuel pipe clip at accelerator control cable bracket.
6. Accelerator control cable bracket.
7. Vacuum lines, noting positions of hoses.
8. Exhaust Gas Recirculation (EGR) valve.
9. Heater inlet pipe hose clamps at heater inlet pipe.
10. Ignition coil assembly front bolts.
11. Loosen ignition coil assembly rear nuts.
12. Alternator braces.
13. Electrical connectors at Idle Air Control (IAC) valve, Mass Air Flow (MAF) and Throttle Position (TP) sensors.
14. Upper intake manifold bolts and studs.
15. Upper intake manifold and gaskets. Discard gaskets.

Disassemble
1. Throttle body from upper intake manifold.
2. Heater hoses from upper intake manifold.
3. Fuel pressure regulator vacuum line.

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

Clean
^ Gasket sealing surfaces.

Assemble
1. Throttle body to upper intake manifold.
2. Heater hoses to upper intake manifold.
3. Fuel pressure regulator vacuum line.

Install or Connect
1. New upper intake manifold gaskets.
2. Upper intake manifold.
^ Guide upper intake manifold beater hoses onto heater inlet pipe.
3. Upper intake manifold bolts and studs.

Tighten
Upper intake manifold bolts and studs to 25 Nm (18 lb. ft.).

4. Heater inlet pipe hose clamps at heater inlet pipe.
5. Alternator braces.
6. Ignition coil assembly front bolts.
7. Tighten ignition coil assembly rear nuts.
8. EGR valve bolts.
9. Vacuum lines as noted during disassembly.
10. Electrical connectors at IAC valve, MAF and TP sensors.
11. Accelerator control cable bracket.
12. Fuel pipe clip at accelerator control cable bracket.
13. Accelerator and cruise control cables at throttle body and accelerator control cable bracket.

Adjust
Adjust throttle and cruise control cables. See Throttle Cable. Adjustments

14. Air inlet duct.
15. Negative battery cable.
16. Refill coolant.