Intake Manifold Replacement

REMOVAL

Figure 28:

1. Disconnect negative cable from auxiliary jumper terminal (Fig. 28).

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

2. Release fuel system pressure.

WARNING: WRAP SHOP TOWELS AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.

3. Disconnect fuel supply tube from rail.

Figure 30:

4. Unplug connectors from MAP and intake air temperature sensors (Fig. 30).
5. Remove plenum support bracket bolt located rearward of MAP sensor.

Figure 29:

6. Remove bolt holding air inlet resonator to intake manifold (Fig. 29).
7. Loosen throttle body air inlet hose clamp.
8. Release snaps holding air cleaner housing cover to housing.
9. Remove air cleaner cover and inlet hoses from engine.

Figure 31:

Figure 32:

10. Unplug TPS and idle air control motor connectors (Figs. 31 & 32).

Figure 33:

11. Squeeze retainer tab on throttle cable and slide cable out of bracket (Fig. 33).
12. Slide speed control cable out of bracket, if equipped.

Figure 34:

13. Remove EGR tube from intake manifold and discard gasket (Fig. 34).
14. Remove plenum support bracket bolt located rearward of EGR tube.

Figure 27:

15. Remove 7 bolts holding upper intake plenum and remove plenum (Fig. 27).
16. Disconnect electrical connectors from fuel injectors.

Figure 35:

17. Remove 4 bolts holding fuel rail (Fig. 35).

Figure 36:

18. Lift fuel rail off engine. There are spacers under each fuel rail bolt (Fig. 36).
19. Remove lower intake manifold attaching bolts. Remove intake manifold.

INSTALLATION

Figure 37:

1. Install intake manifold with new gaskets. Tighten in sequence shown in (Fig. 37) to 21 Nm (185 inch lbs.).
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 Nm (8 ft. lbs.).
4. Attach electrical connectors to fuel injectors.
5. Connect fuel supply tube to fuel rail.
6. Install new gasket and position upper intake plenum to lower manifold. Install plenum bolts and tighten to 18 Nm (13 ft. lbs.).
7. Install bolts at plenum support brackets. Tighten bolts to 18 Nm (13 ft. lbs.).
8. Install EGR tube with new gasket to plenum. Tighten EGR tube to intake manifold plenum screws to 11 Nm (95 inch lbs.).
9. Install throttle and speed control cables.
10. Attach electrical connectors to sensors.
11. Tighten air inlet tube clamps to 3 Nm +1 (25 inch lbs. +5).
12. Connect negative cable to auxiliary jumper terminal.