Intake Manifold: Service and Repair

REMOVAL PROCEDURE
1. Disconnect the negative battery cable.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Remove the intake plenum.
3. Relieve the fuel system pressure.





4. Remove the fuel supply hose from the fuel rail.
5. Remove the fuel return hose from the fuel rail.
6. Remove the fuel injector electrical harness connector.





7. Remove the intake manifold bolts.

Important: Mask off the ports to the intake manifold spacer. Severe damage may result if foreign objects enter the engine.

8. Remove the intake manifold.

Important: Do not damage the machined aluminum surfaces or improper sealing may occur.

9. Clean the intake manifold sealing surfaces with a nonabrasive tool or solvent.

INSTALLATION PROCEDURE





1. Remove the masking from the intake ports.
2. Install the intake manifold.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the intake manifold bolts.
- Tighten the intake manifold bolts to 20 Nm (15 ft lbs).

Note: The manufacture does not provide a torque sequence for this component.

4. Install the fuel injector electrical harness connector.

Important: Counterhold the connections to prevent damage to the fuel rail.





5. Install the fuel supply hose.
- Tighten the fuel supply hose connections to 15 Nm (11 ft lbs).

Important: Counterhold the connections to prevent damage to the fuel rail.

6. Install the fuel return hose.
- Tighten the fuel return hose connections to 15 Nm (11 ft lbs).

7. Install the intake plenum.
8. Reconnect the negative battery cable.
9. Reprogram the applicable accessories.