Intake Manifold

REMOVAL

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.

1. Disconnect negative cable from battery.
2. Remove the inlet air duct from intake manifold to throttle body.
3. Perform fuel system pressure release procedure before attempting any repairs.

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

4. Disconnect fuel supply line quick connect at the fuel tube assembly.
5. Remove fuel rail assembly attaching screws and remove fuel rail assembly from engine. Cover injector holes with suitable covering.

CAUTION: Do not set fuel injectors on their tips, damage may occur to the injectors





Fig. 27





Fig. 28

6. Disconnect brake booster hose (Fig. 27) and PCV hose (Fig. 28) from intake manifold.





Fig. 29

7. Disconnect Manifold Absolute Pressure (MAP) sensor electrical connector (Fig. 29).





Fig. 30

8. Disconnect knock sensor electrical connector (Fig. 30).
9. Disconnect wiring at starter.





Fig. 31

10. Remove the intake manifold to lower support bracket bolts (Fig. 31).
11. Remove intake manifold screws and washers. Discard the fasteners. Remove intake manifold.

INSTALLATION





Fig. 33

Before installing manifold. Clean all mating surfaces. Replace all O-ring gaskets with new gaskets (Fig. 33). All intake manifold fasteners and washers are to be discarded and NEW fasteners and washers are to be used.





Fig. 32

1. Install intake manifold onto cylinder head and tighten fasteners to 12 Nm (105 in. lbs.) in sequence shown in (Fig. 32).
2. Install intake manifold to lower support bracket bolts (Fig. 31). Tighten bolts to 11 Nm (95 in. lbs.).
3. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 in. lbs.).
4. Connect PCV and brake booster hoses.
5. Inspect quick connect fittings for damage, replace if necessary. Apply a light amount of clean engine oil to fuel inlet tube. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
6. Connect Manifold Absolute Pressure (MAP) Sensor wiring connector (Fig. 29).
7. Connect knock sensor connector, and wiring at starter.
8. Install inlet air duct to intake manifold and throttle body. Tighten clamp to 3 Nm (30 in. lbs.).
9. Connect negative cable to battery.
10. With the DRB scan tool use 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.