Removal and Installation

REMOVAL

1. Disconnect battery ground cable.

2. Remove fuel tank filler cap and release fuel tank pressure.

3. Perform fuel pressure release procedures. Service and Repair

4. Disconnect battery ground cable.

Upper Intake Manifold:

5. Remove upper intake manifold.

6. Disconnect fuel supply and return lines from fuel injection supply manifold.

7. Disconnect fuel charging wiring from fuel injectors and valve cover retaining studs. Position fuel charging wiring aside.

8. Disconnect vacuum supply line from fuel pressure regulator and IMRC vacuum motor and valve assembly and position aside.

9. If required, remove fuel injection supply manifold and fuel injectors from lower intake manifold.

10. If required, remove IMRC vacuum motor and valve assembly from lower intake manifold.

11. Remove lower intake manifold to cylinder head retaining bolts in sequence shown.

Lower Intake Manifold Removal Sequence:

12. Remove lower intake manifold from cylinder heads.

Intake Manifold Runner Control:

13. Remove intake manifold gaskets from cylinder heads and discard intake manifold gaskets.

Lower Intake Manifold And Gasket:

NOTE: Using a hand vacuum pump, verify operation of intake manifold runner control vacuum solenoid and plate operation.

INSTALLATION

1. To install, reverse removal procedure using new intake manifold gaskets.

2. Tighten lower intake manifold retaining bolts to 8-12 Nm (71-106 lb in) in sequence shown.

Lower Intake Manifold Installation Sequence:

3. If removed, tighten IMRC vacuum motor and valve assembly retaining bolts to 8-12 Nm (71-106 lb in).

4. Connect fuel supply and return lines.

5. Install fuel tank filler cap at fuel tank.

6. Connect battery ground cable.

7. Add engine coolant if required.

NOTE: Check all connections at fuel injection supply manifold and push on connection fittings to ensure proper engagement.

8. Turn ignition switch ON/OFF several times without starting engine to pressurize system. Check for fuel leaks.

9. START engine and warm to operating temperature. Check for coolant leak if coolant was removed.