Intake Manifold: Service and Repair
Intake Manifold
Material
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure, even when the engine is not running.
1. Relieve the fuel system pressure.
2. Disconnect the battery ground cable.
3. Drain the engine cooling system.
4. Remove the air cleaner outlet tube.
5. Remove the generator.
6. Disconnect the fuel lines.
7. Compress and slide the hose clamp and disconnect the water outlet hose.
8. Remove the accelerator cable splash shield.
9. Disconnect the accelerator and speed control cables and remove the return spring.
10. Position the accelerator cable bracket aside.
^ Remove the bolts.
^ Position the bracket and cables aside.
11. Disconnect the Positive Crankcase Valve (PCV) tube and the vacuum lines.
12. Disconnect the heated PCV coolant hoses.
13. Remove the bolt and position the RH radio ignition interference capacitor aside.
14. Disconnect the vacuum line.
15. Disconnect the five RH fuel injector electrical connectors and five ignition coil electrical connectors.
16. Disconnect the Idle Air Control (IAC) motor electrical connector and the bypass hose.
17. Disconnect the heater hose.
18. Remove the Throttle Body (TB) adapter.
^ Remove the four bolts.
^ Remove the TB adapter.
^ Discard the TB adapter press-in-place gasket.
19. Disconnect the five LH fuel injector electrical connectors and ignition coil connectors.
20. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connectors.
21. Remove the ignition coils.
^ Remove the 10 bolts.
^ Remove the 10 ignition coils.
22. Disconnect the vacuum connector from the fuel pressure regulator.
23. Remove the bolt and position the LH ignition radio ignition interference capacitor aside.
24. Disconnect the Cylinder Head Temperature (CHT) sensor.
25. Remove the water thermostat and housing.
26. Remove the bolts, the upper intake manifold and the intake manifold gaskets. Discard the intake manifold gaskets.
27. Separate the upper and lower intake manifolds.
^ Remove the 10 bolts.
28. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths.
Clean all mating surfaces.
^ Clean the intake manifold mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Installation
1. Position the lower intake manifold to the upper intake manifold and loosely install the 10 bolts.
2. NOTE: Tighten the bolts in two stages.
Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).
3. Position the water thermostat and housing.
4. Install the upper intake manifold.
^ Position the upper intake manifold gaskets and the intake manifold, and loosely install the bolts.
5. Tighten the bolts in two stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
6. Remove and discard the fuel line O-ring seals.
7. NOTE: Lubricate the new fuel line O-ring seals with clean engine oil prior to installation.
Install new fuel line O-ring seals.
8. Connect the fuel lines.
9. Connect the CHT sensor electrical connector.
10. Install the LH radio ignition interference capacitor electrical connector.
11. Connect the vacuum line to the fuel injection supply manifold.
12. Connect the ECT sensor electrical connector.
13. Install the ignition coils.
^ Position the 10 ignition coils.
^ Install the 10 bolts.
14. Connect the five LH fuel injector electrical connectors and five LH ignition coil connectors.
15. Install the TB adapter.
^ Position a new TB adapter press-in-place gasket.
^ Position the TB adapter.
^ Install the four bolts in two stages:
^ Stage 1: Tighten to 9 Nm (80 inch lbs.)
^ Stage 2: Tighten an additional 90°.
16. Connect the coolant hose.
17. Connect the IAC motor bypass hose and connector.
18. Connect the five RH fuel injector electrical connectors and five RH ignition coil connectors.
19. Connect the vacuum line.
20. Install the RH radio ignition interference capacitor.
^ Position the capacitor.
^ Install the bolt.
21. Connect the PCV tube and the vacuum lines.
22. Connect the heated PCV coolant hoses.
23. Install the accelerator bracket.
^ Position the bracket.
^ Install the bolts.
24. Connect the accelerator and speed control cables and return spring.
25. Install the accelerator cable splash shield.
26. Connect the engine water outlet hose and position the hose clamp.
27. Install the generator.
28. Install the air cleaner outlet tube.
29. Connect the battery ground cable.
30. Fill and bleed the cooling system.