Removal and Installation
REMOVAL1. Turn the ignition to the RUN position. Turn on the windshield wipers and cycle wipers to the mid-wipe position (straight up). Turn the ignition switch OFF.
NOTE: When the battery has been disconnected or reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its fuel trim. The vehicle may have to be driven 18 km (10-miles) or more to relearn the fuel trim.
2. Disconnect the battery ground cable.
3. Drain engine cooling system.
4. Remove engine appearance cover.
5. Remove air cleaner outlet tube and engine intake air resonator.
6. Remove wiper module assembly.
7. Relieve fuel system pressure and disconnect fuel lines.
8. Release drive belt tensioner and remove drive belt.
9. Remove two retaining nuts from engine air cleaner outlet tube bracket and remove engine air cleaner outlet tube bracket.
10 Remove eight retaining nuts on RH and LH ignition wire covers and remove ignition wire covers.
CAUTION: Do not pull on ignition wire as it may separate from the connector in the ignition wire boot.
11. Disconnect ignition wires from spark plugs with a gentle twist and pull motion on the spark plug boot.
12. Disconnect ignition wires from ignition coils.
13. Detach two center ignition wire separators from generator mounting bracket.
14. Remove ignition wires.
15. Disconnect generator wiring harness from generator at battery positive terminal and disconnect stator connector plug. Disconnect wiring harness retaining clip from generator mounting bracket.
16. Remove two bolts and two nuts attaching generator mounting bracket to generator and intake manifold. Remove generator mounting bracket.
17. Disconnect upper radiator hose and water bypass tube to thermostat hose at water bypass tube.
18. Disconnect engine control sensor wiring from both Engine Coolant Temperature (ECT) sensor and water temperature indicator sender unit connectors at bottom of water bypass tube.
19. Remove two retaining nuts from water bypass tube hold down braces to intake manifold studs and remove water bypass tube.
20. Remove two bolts retaining generator to cylinder block and remove generator.
21. Disconnect accelerator cable and speed control actuator cable from throttle body and from accelerator cable bracket and move aside.
22. Disconnect chassis vacuum supply hose from intake manifold connector and move out of the way.
23. Disconnect vacuum harness from fuel pressure regulator, RH and LH Intake Manifold Runner Control (IMRC) vacuum controls, Exhaust Gas Recirculation (EGR) Control Valve, EGR vacuum regulator solenoid, and IMRC vacuum control solenoids and intake manifold connection. Remove vacuum harness.
24. Disconnect crankcase vent connector and hose from throttle body. Remove Positive Crankcase Ventilation (PCV) Valve from LH valve cover and move crankcase vent connector hose and PCV valve out of the way.
PCV System:
25. Disconnect four engine wiring harness retaining clips from intake manifold studs and one clip from fuel pressure regulator bracket.
26. Disconnect eight fuel charging wiring connectors at fuel injectors.
27. Remove upper bolt retaining accelerator cable bracket to LH cylinder head. Loosen lower bolt retaining accelerator cable bracket to LH cylinder head and position accelerator cable bracket to LH cylinder head against LH valve cover.
28. Remove two retaining bolts attaching EGR valve and EGR valve gasket to intake manifold.
29. Loosen and remove 20 bolts and studs retaining intake manifold to cylinder heads following the de-torque sequence.
30. Lift fuel charging wiring upward for intake manifold removal clearance.
31. Lift front of intake manifold and IMRC assembly and move assembly forward to obtain access to rear of intake manifold. Disconnect fuel charging wiring connectors from idle air control valve, throttle position sensor and harness clip to idle air control valve retaining stud.
32. Remove intake manifold.
33. Remove four fuel injection supply manifold retaining bolts and two pressure regulator bracket bolts from intake manifold. Remove the fuel injection supply manifold from fuel injectors.
34. Remove four bolts retaining RH and LH IMRC assemblies to intake manifold and remove IMRC assemblies.
NOTE: Intake manifold upper gaskets must be replaced when intake manifold retaining bolts have been loosened.
35. Remove intake manifold upper gaskets and all load limiting spacers from RH and LH IMRC assemblies and discard.
36. Remove lower intake manifold gaskets from cylinder heads and discard.
37. Remove EGR valve gasket and discard. Clean EGR valve gasket sealing surface on both EGR valve and intake manifold.
INSTALLATION
NOTE: If new intake manifold or IMRC assembly is being installed, transfer all necessary components onto new intake manifold or IMRC assembly using new gaskets.
1. Clean and inspect all sealing surfaces. Upper sealing surfaces or IMRC assemblies and intake manifold mating surfaces should be cleaned with a suitable solvent to remove adhesive residue. Inspect intake manifold mating surfaces and upper IMRC assembly surfaces to ensure that no load limiting spacers (washers) are stuck to the sealing surfaces. The load limiting spacers are part of the intake manifold upper gasket. New load limiter spacers will be included with the replacement intake manifold upper gasket as an assembly.
2. Remove protective paper from adhesive backing on intake manifold upper gasket and install onto top of RH IMRC assembly using tapered pins at end bolt hole locations for proper gasket alignment. Repeat same procedure for LH assembly.
3. Assemble IMRC assemblies to intake manifold and install four IMRC retaining bolts. Finger tighten bolts.
4. Install fuel injection supply manifold onto fuel injectors and install four retaining bolts. Tighten to 8-12 Nm (71-106 lb in). Install two fuel pressure regulator bracket retaining screws. Tighten to 8-12 Nm (71-106 lb in).
5. Position new intake manifold gaskets onto cylinder heads using integral locating pins to align gaskets.
6. Place intake manifold under fuel charging wiring and connect fuel charging wiring to idle air control valve and throttle position sensor. Connect wiring clip to idle air control valve retaining stud.
7. Move intake manifold into position and install new EGR valve gasket and two EGR valve retaining bolts. Finger tighten bolts.
8. Install 10 longer bolts and stud bolts in outer bolt holes of intake manifold. Do not tighten.
9. Install 10 shorter bolts and stud bolts in inner bolt holes of intake manifold. hand tighten all 20.
10. Tighten fasteners in numerical torquing sequence as follows:
- Fasteners 5,7,9 and 11 to 12-15 Nm (8.8-11.0 lb ft).
- All other fasteners to 18-22 Nm (13-16 lb ft).
- Then tighten all fasteners in numerical sequence by rotating an additional 85-95 degrees.
11. Tighten four intake manifold to IMRC retaining bolts A-D in (see diagram) to 8-10 Nm (71-89 lb in). Tighten fasteners A through D in alphabetical sequence by rotating 85-95 degrees.
12. Tighten two EGR valve retaining bolts to 20-30 Nm (15-22 lb ft).
13. Install upper retaining bolt into accelerator cable bracket and tighten both upper and lower retaining bolts to 20-30 Nm (15-22 lb ft).
14. Connect fuel charging wiring harness retaining clips to intake manifold studs and connect harness clip to fuel pressure regulator bracket.
15. Connect four fuel charging wiring harness retaining clips to intake manifold studs and connect harness clip to fuel pressure regulator bracket.
16. Connect crankcase vent connector and hose to throttle body connection and install PCV valve into crankcase ventilation grommet on LH valve cover.
PCV System:
17. Connect vacuum harness to fuel pressure regulator, RH and LH IMRC vacuum controls, EGR valve, EGR vacuum regulator solenoid and IMRC vacuum control solenoids and intake manifold vacuum at rear connection.,
18. Connect chassis vacuum supply hose and spring clamp to intake manifold vacuum at forward connection.
19. Connect accelerator cable and speed control actuator cable to throttle body. Connect cables to accelerator cable bracket.
20. Replace O-ring seals on water bypass tube as required. Replace center O-ring seal on water bypass tube if needed.
CAUTION: Do not cut O-ring seal during water bypass tube installation into cylinder heads or possible engine coolant leakage may occur.
21. Clean O-ring sealing surface on cylinder heads and coat water bypass tube sealing O-rings with coolant system fluid. Insert water bypass tube support braces over intake manifold inner studs and press water bypass tube into position.
22. Install two water bypass tube retaining nuts and tighten to 8-12 Nm (71-106 Lb in).
23. Connect engine control sensor wiring to the ECT and water temperature indicator sender unit connectors.
24. Verify conductivity of water temperature indicator sender unit using a multi-meter on ohms selection. Touch body of water temperature indicator sender unit with probe and other probe to ground. If more than 1 ohm of resistance, remove water bypass tube and remove paint on the bottom of mounting tabs to restore a good ground connection.
25. Connect upper radiator hose and water bypass tube to water thermostat housing hose at water bypass tube.
26. Position generator on cylinder block and install two retaining bolts. Tighten bolts to 20-30 Nm (15-22 lb ft).
27. Position generator mounting bracket and install two front retaining bolts and two rear nuts. tighten to 8-12 Nm (15-22 lb ft).
28. Connect generator wiring harness connector plug and battery positive terminal wire to generator. Connect wiring harness retaining clip to generator mounting bracket.
29. Position ignition wires and connect two center ignition wire separators to generator mounting bracket.
NOTE: Make sure ignition wire clips are fully seated to ignition coils.
30. Connect ignition wires to ignition coils
31. Connect ignition wires as numbered to proper cylinder spark plugs.
32. Install ignition wire rubber separators into valve cover slots and install ignition wire covers. Install eight retaining nuts and tighten to 2-4 Nm (18-35 lb in).
33. Position engine air cleaner outlet tube bracket on RH valve cover and install two retaining nuts. Tighten to 8-12 Nm (71-106 lb in).
34. Install drive belt.
35. Connect fuel tubes.
36. Install air cleaner outlet tube, engine intake air resonator and engine appearance cover.
37. Install windshield wiper module assembly.
CAUTION: Use extreme care to keep coolant mixture off of drive belt and pulleys. If needed, remove drive belt and rinse with clear water. Clean pulleys and install drive belt. Drive belt squeal and early drive belt fatigue will occur otherwise.
38. Close radiator draincock and fill engine cooling system.
39. Install engine appearance cover.