Removal and Installation
Intake Manifold - 4.6LMaterial:
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
1. Remove the engine cover.
2. Disconnect the fuel supply hose spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
3. Disconnect the battery ground cable. For additional information, refer to Battery.
4. Drain the cooling system. For additional information, refer to Cooling System.
5. Loosen the clamp, remove the 4 nuts and position the engine air cleaner (ACL) aside to gain access to the mass airflow (MAF) sensor electrical connector.
6. Disconnect the MAF sensor electrical connector and remove the ACL.
7. Disconnect the crankcase ventilation tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
8. Loosen the clamp and remove the air cleaner outlet pipe.
9. Remove the transmission fluid level indicator and tube bolt.
10. Remove the bolt and position the transmission fluid indicator and tube aside.
11. Compress and slide the hose clamp and disconnect the upper radiator hose.
12. Disconnect the heater coolant hose.
13. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
Disconnect the electronic throttle control electrical connector.
14. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
Disconnect the throttle position (TP) sensor electrical connector.
15. Disconnect the exhaust gas recirculation (EGR) system module electrical connector.
16. Disconnect the vacuum hoses from the EGR system module.
17. Disconnect the upper and lower fittings and remove the exhaust manifold-to-EGR system module tube.
18. Disconnect the hoses and the positive crankcase ventilation (PCV) valve tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
19. Disconnect the vacuum harness connector.
20. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to Heating and Air Conditioning.
21. Disconnect the evaporative emissions system (EVAP) vapor hose quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
22. Remove the 4 bolts, and the throttle body (TB) and adapter as an assembly.
^ Discard the TB adapter gasket.
23. Disconnect the 8 coil-on-plug electrical connectors.
24. Disconnect the 8 fuel injector electrical connectors.
25. Remove the 8 bolts and the 8 ignition coils.
26. Rotate the tensioner clockwise and remove the accessory drive belt from the generator pulley.
27. Remove the 3 bolts and the generator support bracket.
28. Disconnect the injection pressure (IPR) sensor vacuum hose and the electrical connector.
29. Remove the 2 bolts, thermostat housing and thermostat.
^ Discard the thermostat O-ring seal.
30. Remove the 9 intake manifold bolts.
31. Remove the intake manifold and discard the intake manifold gaskets.
^ Inspect the intake manifold assembly for damage.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which can cause leak paths. Use a plastic scraping tool to clean sealing surfaces.
Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
2. Position new intake manifold gaskets, the intake manifold and loosely install the 9 bolts.
3. Using a new O-ring seal, install the thermostat.
4. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
Install the thermostat housing and loosely install the 2 bolts.
5. Tighten the 11 bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
6. Connect the IPR sensor electrical connector and the vacuum hose.
7. Install the generator support bracket and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
8. Rotate the tensioner clockwise and install the accessory drive belt onto the generator pulley.
9. Install the 8 ignition coils and the 8 bolts.
^ Tighten to 6 Nm (53 inch lbs.).
10. Connect the 8 fuel injector electrical connectors.
11. Connect the 8 coil-on-plug electrical connectors.
12. Install a new TB adapter gasket, position the TB adapter assembly and tighten the 4 bolts in 2 stages.
^ Stage 1: Tighten to 9 Nm (80 inch lbs.).
^ Stage 2: Tighten an additional 90 degrees.
13. Connect the EVAP vapor hose quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
14. Connect the vacuum harness connector.
15. If equipped, connect the auxiliary heater hoses. For additional information, refer to Heating and Air Conditioning.
16. Connect the hoses and the PCV valve tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
17. Install the exhaust manifold-to-EGR system module tube.
^ Hand-tighten the upper and lower fittings.
^ Tighten to 40 Nm (30 ft. lbs.).
18. Connect the vacuum hoses at the EGR system module.
19. Connect the EGR system module electrical connector.
20. Connect the fuel hose spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
21. Connect the TP sensor electrical connector.
^ Push in the red clip.
22. Connect the electronic throttle control electrical connector.
^ Push in the red clip.
23. Install the upper radiator hose and position the clamp.
24. Connect the heater coolant hose.
25. Position the transmission fluid indicator and tube and install the retaining bolt.
^ Tighten to 10 Nm (89 inch lbs.).
26. Install the transmission fluid tube and indicator bolt.
^ Tighten to 10 Nm (89 inch lbs.).
27. Install the air cleaner outlet pipe and tighten the clamp.
28. Connect the crankcase ventilation tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
29. Connect the MAF sensor and position the ACL.
30. Tighten the clamp and install the 4 nuts.
^ Tighten to 7 Nm (62 inch lbs.).
31. Install the engine cover.
32. Connect the battery ground cable. For additional information, refer to Battery.
33. Fill and bleed the engine cooling system. For additional information, refer to Cooling System.