Intake Plenum Replacement

Intake Plenum Replacement

Removal Procedure






1. Remove the intake plenum air inlet hose clamps and hoses from the throttle body.
2. Disconnect the fuel pressure regulator atmospheric vent tube from the bottom of the throttle body.






3. Remove the bolts securing the throttle body to the intake plenum.
4. Remove the throttle body from the intake plenum and crankcase vent adapter, allowing it to be supported by the throttle body inlet heater hose.
5. Remove the throttle body O-ring seals.






6. Remove the 3 bolts securing the crankcase vent adapter to the intake plenum.
7. Lift the crankcase vent adapter from the intake plenum, and position aside.






8. Disconnect the vacuum brake booster hose retainer (1) from the rear of the intake plenum-RHD only.
9. Disconnect the crankcase ventilation dirty air hose retainer (2) from the fuel pipe.






10. Remove the remote power steering fluid reservoir mounting bolts (1, 3) ONLY, and position aside.






11. Disconnect the electrical connector (1) and vacuum hose (2) from the switchover valve at the rear of the plenum.






12. Remove the bolt (1) securing the throttle body heater inlet hose/pipe to the intake plenum (2).
13. Disconnect the vacuum brake booster hose (3) from the vacuum source.






14. Remove the 2 bolts securing the engine control module (ECM) bracket to the intake plenum.






15. Remove the intake plenum bolt caps.
16. Remove the intake plenum bolts.
17. Lift the intake plenum from the intake manifold.
18. Remove the intake plenum O-ring seals.
19. Mask off the open ports to the intake manifold, in order to prevent foreign objects from entering the engine.
20. Disassemble the intake plenum if necessary. Refer to Intake Plenum Manifold Disassemble.
21. Clean and inspect the intake plenum. Refer to Intake Plenum Manifold Cleaning and Inspection.

Installation Procedure

1. Assemble the intake plenum if necessary. Refer to Intake Plenum Manifold Assemble.
2. Remove the masking from the intake plenum ports and ensure the sealing surfaces are clean and dry.
3. Lightly coat the intake plenum O-ring seals with clean engine oil and install to the intake manifold.






4. Position the intake plenum to the intake manifold, aligning the pins.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the intake plenum bolts. Tighten the intake plenum bolts to 20 Nm (15 lb ft).
6. Install the intake plenum bolt caps.






7. Install the 2 bolts securing the ECM bracket to the intake plenum. Tighten the ECM bracket bolts to 8 Nm (71 lb in) in sequence 2-3.






8. Connect the vacuum brake booster hose (3) to the vacuum source.
9. Install the bolt (1) securing the throttle body heater inlet hose/pipe to the intake plenum (2). Tighten the throttle body heater inlet hose/pipe bolt to 9 Nm (80 lb in).






10. Connect the electrical connector (1) and vacuum hose (2) to the switchover valve at the rear of the plenum.






11. Position the remote power steering fluid reservoir (2) to the engine.
12. Install the remote power steering fluid reservoir mounting bolts (1, 3).
- Tighten the remote power steering fluid reservoir mounting bolts (1) to intake plenum to 9 Nm (80 lb in).
- Tighten the remote power steering fluid reservoir mounting bolt (3) to cylinder head to 25 Nm (18 lb ft).






13. Connect the vacuum brake booster hose retainer (1) to the rear of the intake plenum-RHD only.
14. Connect the crankcase ventilation dirty air hose retainer (2) to the fuel pipe.






15. Apply clean engine oil to the crankcase vent adapter seal.
16. Position the crankcase vent adapter to the intake plenum.
17. Install the 3 bolts securing the crankcase vent adapter to the intake plenum. Tighten the crankcase vent tube adapter bolts to 8 Nm (71 lb in).
18. Inspect the following O-ring seals and replace if necessary:
- The throttle body.
- The crankcase vent tubes.
19. Lightly lubricate the O-ring seals with clean engine oil.






20. Position the throttle body to the intake plenum and crankcase vent adapter.
21. Install the bolts securing the throttle body to the intake plenum. Tighten the throttle body bolts to 8 Nm (71 lb in).
22. Connect the fuel pressure regulator atmospheric vent tube to the bottom of the throttle body.






23. Install the intake plenum air inlet hose clamps and hoses to the throttle body.