Intake Manifold and Manifold Spacer Replacement

TOOLS REQUIRED
- J-43914 Hose Clamp Pliers

REMOVAL




1. Disconnect the negative battery cable.
2. Remove both intake runners.
3. Remove intake plenum.
4. Relieve fuel system pressure. Refer to "Fuel System Pressure Relief" procedure. Service and Repair

IMPORTANT: Note: If injectors are not being replaced, it is not necessary to remove fuel rail from manifold when removing manifold.




5. Remove fuel supply hose from fuel rail.
6. Remove fuel return hose from fuel rail.
7. Remove fuel injector electrical harness connector.
8. Remove fuel injector connector.
9. Remove fuel rail.




10. Remove intake manifold bolts.
11. Remove manifold spacer bolts.
12. Remove manifold spacer.
13. Remove O-ring gaskets.

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

14. Clean intake manifold sealing surfaces with a non-abrasive tool or solvent.

INSTALLATION




1. Install manifold spacer seals.
2. Install intake manifold spacer.

Torque: 20 N.m (15 ft-lbs)

3. Install intake manifold seals.
4. Install intake manifold.

Torque: 20 N.m (15 ft-lbs)




5. Install fuel injector electrical harness and connectors.




6. Install fuel rail.

Torque: 8 N.m (71 in-lbs)

7. Install fuel supply hose.
8. Install fuel return hose.
9. Tighten fuel return hose connections.

Torque: 15 N.m (11 ft-lbs)

10. Install intake plenum.
11. Reconnect negative battery cable.