Intake Manifold: Service and Repair
REMOVAL PROCEDURE^ Tools Required
- J 37088 Fuel Line Quick Connect Separator Tool Set
1. Remove the negative battery cable.
2. Remove the intake manifold sight shield-four nuts (1).
3. Relieve the fuel system pressure.
4. Remove the air intake duct from the throttle body.
5. Remove the transaxle vent hose and transaxle shift cable at the bracket.
6. Remove the TP sensor and IAC valve connectors.
7. Remove the accelerator cable and cruise control cable at the throttle body.
8. Disconnect the spark plug wires from the left bank spark plugs and the molded retainers in the intake manifold. Lay the wires aside.
9. Remove the throttle body coolant hoses at the throttle body and the surge tank pipe.
10. Disconnect the PCV valve and both feed tubes (1) from the camshaft covers.
11. Disconnect the EGR and crankcase ventilation pipe at the throttle body spacer.
12. Remove the brake booster vacuum hose at the intake manifold vacuum fitting.
13. Remove the fuel rail ground wire at the rear cylinder head.
14. Disconnect the fuel rail bracket retaining bolt (3) at the rear lift bracket.
15. Remove the quick-connect fittings at the fuel rail.
15.1. Grasp both sides of the fitting.
15.2. Twist the female connector 1/4 turn in each direction to loosen any dirt within fitting.
CAUTION: SAFETY GLASSES MUST BE WORN WHEN USING COMPRESSED AIR, AS FLYING DIRT PARTICLES MAY CAUSE EYE INJURY.
15.3. Blow the dirt out of the fitting using compressed air.
15.4. Choose the correct tool from the J 37088 for the size of the fitting. Insert the tool into the female connector, then push/pull inward to release the locking tabs.
15.5. Pull the connection apart.
^ Using a clean shop towel, wipe off the male pipe end. Inspect both ends of the fitting for dirt and burrs.
^ Clean or replace the components or assemblies as required.
16. Disconnect the fuel rail bracket at the EGR valve.
17. Disconnect the injector harness main connector.
18. Remove the purge solenoid harness by removing the retaining bolt and disconnecting from the intake manifold.
19. Disconnect the throttle body heater hose (3) from the water crossover.
20. Disconnect the generator coolant inlet hose from the heater outlet pipe and remove from the intake manifold studs.
21. Disconnect the throttle body heater outlet hose from the throttle body and remove the coolant overflow pipe from the intake manifold studs.
IMPORTANT: The intake manifold carrier gaskets are attached to the intake manifold through a snap-lock feature. When removing the intake manifold, the carrier gaskets will remain attached to the manifold.
22. Remove six bolts, four studs and the intake manifold.
IMPORTANT: Do not replace the intake manifold gaskets after intake manifold removal. The gaskets are reusable. The gaskets should only be replaced if the plastic housing or rubber seals are damaged.
23. Remove the four throttle body (4) to spacer (1) retaining bolts.
24. Remove the throttle body gasket (1) and discard. Make sure all gasket material is removed.
25. Remove the throttle body spacer retaining bolts (2) and throttle body spacer (1) from the intake manifold.
26. Remove the MAP sensor from the top of the spacer mounting location.
27. Disconnect the eight fuel rail snap lock retainers by squeezing the tab and lifting the fuel rail simultaneously.
28. Disconnect the fuel regulator vacuum tube.
29. Remove the brake booster vacuum hose.
30. Lift the entire fuel rail and injector assembly from the intake manifold when all eight snap lock retainers are released.
INSTALLATION PROCEDURE
1. Clean any debris from the cylinder head or intake manifold gaskets. Place the intake manifold in position on the cylinder heads.
IMPORTANT: The intake manifold carrier gaskets are attached to the intake manifold through a snap-lock feature. When you install the intake manifold, the carrier gaskets will remain attached to the manifold. It is not necessary to replace the gaskets unless there is damage to the seals.
2. Install the six bolts and four studs.
^ Tighten the intake manifold bolts and studs starting from the center and working outward in a circular pattern to 10 Nm (89 in. lbs.).
IMPORTANT: The following steps are only necessary if the throttle body or intake manifold required replacement.
3. Make sure all mating surfaces for the throttle body spacer and throttle body are clean. Any debris or flawed sealing surfaces could cause vacuum leaks and hinder engine performance.
4. Install the throttle body spacer (1) retaining bolts (2) and throttle body spacer to the intake manifold.
^ Tighten the throttle body spacer bolts (2) to 12 Nm (106 in. lbs.).
5. Install a new throttle body gasket (1) on the throttle body. Make sure all the old gasket material has been removed.
6. Install the four throttle body retaining bolts.
^ Tighten the upper throttle body retaining bolts to 12 Nm (106 in. lbs.).
^ Tighten the lower throttle body retaining bolts to 10 Nm (89 in. lbs.).
7. Press the MAP sensor in position at the top of the spacer mounting location.
8. Align the fuel rail snap lock retainers and fuel injectors in position on the intake manifold.
9. Snap the entire fuel rail and injector assembly into the intake manifold by pressing the fuel rail and injector simultaneously into correct position. DO NOT force the injector into position or damage to the O-ring seals could occur.
10. Connect the fuel regulator vacuum tube.
11. Install the brake booster vacuum hose.
12. Connect the throttle body coolant hose to the water crossover.
13. Connect the fuel rail ground wire at the rear cylinder head.
^ Tighten the fuel rail ground wire retaining bolt to 11 Nm (97 in. lbs.).
14. Install the quick connect fittings to the fuel rail.
14.1. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet tubes.
14.2. Push both sides of the fitting together in order to snap the retaining tabs/fingers into place.
14.3. Once installed, pull on both sides of the fitting to make sure the connection is secure.
15. Install the fuel rail bracket retaining bolt at the rear left lift bracket.
^ Tighten the fuel rail bracket retaining bolt to 4 Nm (35 in. lbs.).
16. Install the purge solenoid harness and retaining bolt. Connect the hose to the intake manifold.
^ Tighten the purge solenoid harness retaining bolt to 12 Nm (106 in. lbs.).
17. Connect the throttle body coolant outlet hose to the throttle body and place the coolant overflow pipe retaining tabs on the intake manifold studs.
18. Connect the generator coolant inlet hose to the heater outlet pipe and place the retaining tabs on the intake manifold studs.
19. Connect the PCV valve and both feed tubes to the camshaft covers.
20. Connect the EGR and crankcase ventilation pipe at the throttle body spacer.
21. Route the left bank spark plug wires as shown to prevent wire damage.
22. The left bank wires must be secured in the retaining features formed into the intake manifold.
23. Install the accelerator cable and cruise control cable at the throttle body.
24. Install the TP sensor and IAC valve connectors.
25. Install the transaxle vent hose and the transaxle shift cable at the bracket.
26. Install the air intake duct.
27. Connect the negative battery cable.
28. To clean, turn the ignition switch to the ON position for two seconds, then turn to the OFF position for ten seconds. Again turn to the ON position and check for fuel leaks.
29. Install the four intake manifold sight shield nuts.
^ Tighten the nuts to 3 Nm (27 in. lbs.).