Intake Manifold Replacement

REMOVAL
1. Disconnect negative battery cable.
2. Perform fuel system pressure release and fuel rail purge procedure, before attempting any repairs.

Figure 8 Air Cleaner Assembly - Roadster:

3. Disconnect intake air temperature sensor electrical connector from air cleaner. Remove throttle body hoses and air cleaner assembly.

Figure 9 Throttle Cables Attachment:

4. Remove throttle cable.
5. Disconnect the Crankcase Ventilation (CCV) and canister purge hoses.

Figure 10 Electrical Connection To Throttle Body:

6. Disconnect Throttle Position Sensor (TPS) electrical connector from intake manifold.

Figure 11 Brake Booster Hose:

7. Remove brake booster hose from air intake plenum.

Figure 12 Idle Air Control (IAC) Motor Electrical And Hose:

8. Disconnect Idle Air Control (IAC) motor electrical and hose connection.
9. Remove cowl cover.

Figure 13 Coil Electrical Connectors:

10. Disconnect the electrical connectors at the ignition coils.

Figure 14 Intake Manifold Electrical Connectors:

11. Disconnect the two electrical connectors on the left rear plenum.

Figure 15 Quick Connect Fuel Fitting To Fuel Line:

12. Remove the fuel hose quick connect fitting from the fuel line. Use an open end wrench to push in on the plastic ring located on the end of the fitting. Gently pull the fitting from the fuel rail.

WARNING: Wrap a shop towel around hose to catch any gasoline spillage.

13. Remove intake manifold bolts. Lift the front of intake manifold and pull forward to remove.
14. Cover intake manifold with suitable cover when servicing.

INSTALLATION

CAUTION: When cleaning the cylinder head and block mating surfaces, do not use a metal scraper because the surfaces could be cut or ground. Instead, use a wooden or plastic scraper.

1. Remove covering on intake manifold and clean surface.
2. Clean all surfaces of cylinder block and cylinder heads.

Figure 16 Crankcase Ventilation (CCV) System:

NOTE: Be sure that the CCV hose is installed into the grommet before installing intake manifold.

Figure 17 Intake Manifold Gaskets Installation:

3. Carefully install the intake manifold gaskets.

Figure 18 Intake Manifold Bolt Torque Sequence:

4. Set intake manifold in position on the engine. Install intake manifold bolts and tighten initially to 1 Nm (10 inch lbs.). Then tighten bolts to 11 Nm (95 inch lbs.) in sequence shown.
5. Lubricate the end of the chassis fuel tube with 30 weight oil. Connect fuel supply hose to chassis fuel tube assembly. Pull backward on the quick connect fitting to ensure complete insertion.
6. Connect. Idle Air Control (IAC) electrical and hose connectors.
7. Connect. CCV and canister purge hoses to intake plenum.
8. Connect brake booster hose to intake plenum
9. Connect ignition coils and the two electrical connectors at rear of engine.
10. Install cowl cover.
11. Connect the wiring connector to the throttle position sensor (UPS).
12. Install throttle cable.
13. Install air c leaner and throttle body hose assemblies. Connect intake air temperature sensor electrical connector to air cleaner assembly.
14. Connect negative battery cable.
15. With the DRB III Scan Tool, use the ASD Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF: position, or Stop All Test is selected.