Intake Manifold and Manifold Spacer Replacement

INTAKE MANIFOLD AND MANIFOLD SPACER REPLACEMENT (IN-VEHICLE)

- TOOLS REQUIRED
- J43914 Universal Clamp Pliers
- SA9805E Fuel Line Separator

REMOVAL





1. Disconnect negative battery cable.
2. Remove intake plenum.





3. Relieve fuel system pressure.
4. Remove fuel supply hose from the fuel rail using Fuel Line Separator SA9805E.
5. Remove fuel return hose from the fuel rail using fuel line separator SA9805E.
6. Disconnect fuel injector electrical harness connector.
7. Remove fuel injector connectors.
8. Remove fuel injector harness.
9. Remove fuel rail bolts.
10. Remove fuel rail.





11. Remove intake manifold bolts.
12. Remove intake manifold.

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

13. Remove manifold spacer bolts.
14. Remove manifold spacer.

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

15. Remove sealing rings.
16. Clean manifold sealing surfaces with a nonabrasive tool or solvent.

INSTALLATION

1. Remove masking from intake ports.
2. Install manifold gaskets.
3. Install manifold spacer.
4. Install manifold spacer bolts. Apply Loctite (R) 242 threadlocker (or equivalent) to bolts.

Torque:
Intake Manifold Spacer Bolt: 20 Nm (15 ft.lbs)

5. Install intake manifold gaskets.
6. Install intake manifold.
7. Install intake manifold bolts. Apply Loctite (R) 242 threadlocker (or equivalent) to bolts.

Torque:
Intake Manifold Bolt: 20 Nm (15 ft.lbs)

8. Install the fuel injector electrical harness and connectors.
9. Install fuel rail.

Torque:
Fuel Rail Bolts: 8 Nm (71 in.lbs)

10. Connect fuel supply hose.
11. Connect fuel return hose.
12. Install upper intake plenum.
13. Install plenum bolts and EGR housing bolt.

Torque:
Intake Plenum Bolts: 8 Nm (71 in.lbs)

14. Install intake plenum clamp using Universal Clamp Pliers J43914.
15. Reconnect negative battery cable.
16. Crank engine but do not start. Check for fuel leaks.