Intake Manifold Replacement
Intake Manifold ReplacementRemoval Procedure
1. Remove the intake plenum.
2. Relieve the fuel system pressure.
3. Refer to Quick Connect Fitting(s) Service (Metal Collar) in order to disconnect the following quick connect fittings from the fuel rail:
^ The return hose/pipe (1)
^ The feed hose/pipe (2)Plug the open outlet ports to prevent fuel loss and contamination.
4. Disconnect the fuel injector electrical harness connector (2) from the engine wiring harness connector (3).
5. Disconnect the fuel pressure regulator vent tube from the fuel pressure regulator.
6. Remove the fuel rail if intake manifold replacement is necessary.
7. Remove the intake manifold bolts (1).
8. Remove the intake manifold (2) from the intake manifold flange.
9. Remove the seals (3).
10. Mask off the open ports to the intake manifold flange, in order to prevent foreign objects from entering the engine.
11. If necessary, disassemble the intake manifold.
12. Clean and inspect the intake manifold.
Installation Procedure
1. If necessary, assemble the intake manifold.
2. Remove the masking from the intake manifold flange and ensure the sealing surfaces are clean and dry.
3. Install the seals (3) into the intake manifold flange grooves.
4. Position the intake manifold (2) to the intake manifold flange.
Notice: Install the intake manifold bolts (1).
5. Tighten the intake manifold bolts to 20 Nm (15 ft. lbs.).
6. Install the fuel rail if previously removed.
7. Connect the fuel pressure regulator vent tube to the fuel pressure regulator.
8. Connect the fuel injector electrical harness connector (2) to the engine wiring harness connector (3).
9. Refer to Quick Connect Fitting(s) Service (Metal Collar) in order to connect the following quick connect fittings to the fuel rail:
^ The feed hose/pipe (2)
^ The return hose/pipe (1)
10. Install the intake plenum.