Intake Manifold and Manifold Spacer Replacement

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 in the fuel system.

IMPORTANT: 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.
3. Apply Loctite 242(R) thread locker (or equivalent) to intake manifold spacer bolts and install bolts using torque sequence.

Torque:
Intake Manifold Spacer Bolt: 20 N.m (15 ft-lbs)




4. Install intake manifold seals.
5. Install intake manifold.
6. Apply Loctite 242(R) thread locker (or equivalent) to intake manifold bolts and install bolts.

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




7. Install fuel injector electrical harness and connectors.




8. Install fuel rail.

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

9. Install fuel supply hose.
10. Install fuel return hose.
11. Tighten fuel return hose connections.

Torque:
Fuel Return Hose Connections: 15 N.m (11 ft-lbs)

12. Install intake plenum.
13. Install intake runners.
14. Connect negative battery cable.

Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)