Intake Manifold Replacement

Intake Manifold Replacement

^ Tools Required
- J 43914 Universal Clamp Pliers
- SA9805E Fuel Line Separator

Removal Procedure





1. Disconnect the negative battery cable.
2. Remove the intake plenum. Intake Plenum Replacement.





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





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

Notice: Use extreme care and do not damage or scratch the machined aluminum surfaces. Leaks will result.

13. Remove the manifold spacer bolts.
14. Remove the manifold spacer.
15. Remove the sealing rings.
16. Clean the manifold sealing surfaces with a nonabrasive tool or solvent.

Installation Procedure





1. Remove the masking from the intake ports.
2. Install the manifold gaskets.
3. Install the manifold spacer.
4. Install the manifold spacer bolts. Apply LOCTITE 242 threadlocker, or equivalent, to the bolts.
^ Tighten the intake manifold spacer bolt to 20 Nm (15 ft. lbs.).
5. Install the intake manifold gaskets.
6. Install the intake manifold.
7. Install the intake manifold bolts. Apply LOCTITE 242 threadlocker, or equivalent, to the bolts.
^ Tighten the intake manifold bolt to 20 Nm (15 ft. lbs.).





8. Install the fuel injector electrical harness and connectors.
9. Install the fuel rail.
^ Tighten the fuel rail bolts to 8 Nm (71 inch lbs.).





10. Connect the fuel supply hose.
11. Connect the fuel return hose.
12. Install the upper intake plenum.
13. Install the plenum bolts and EGR manifold bolt.
^ Tighten the intake plenum bolts to 8 Nm (71 inch lbs.).
^ Tighten the EGR manifold bolt to 8 Nm (71 inch lbs.).
14. Install the intake plenum clamp using the J 43914.
15. Connect the negative battery cable.
^ Tighten the battery terminal bolts to 17 Nm (13 ft. lbs.).
16. Crank the engine but do not start. Check for fuel leaks.