Intake Manifold Assembly

Intake Manifold Assembly

Material:

Disassembly

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. Failure to follow these instructions can result in personal injury.

1. Remove the 4 fuel rail stud bolts.

2. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will make removal of the fuel rail easier.

Separate the fuel rail from the fuel injectors and remove the fuel rail.
3. Remove fuel injectors.
^ Discard the O-ring seals.

4. Disconnect and remove the positive crankcase ventilation (PCV) coolant hose.
5. Remove the 4 throttle body (TB) bolts and the TB.
^ Discard the TB gasket.

6. Remove the exhaust gas recirculation (EGR) system module bolts and the EGR system module.
^ Discard the EGR system module gasket.

7. Remove the 6 coolant bypass tube bolts.
8. Remove the coolant bypass tube
^ Discard the gaskets.

Assembly
1. Position new coolant bypass tube gaskets, the coolant bypass tube and install the 6 bolts.
^ Tighten to 10 Nm (89 inch lbs.).

2. Install a new EGR gasket (with the raised gasket surface facing the throttle body spacer) and the EGR system module and the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





3. Install a new throttle body gasket and the throttle body and tighten the 4 throttle body bolts in 2 stages.
^ Stage 1: Tighten to 9 Nm (80 inch lbs.).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).

4. Install the PCV coolant hose.

5. NOTE: Install new fuel injector O-ring seals on the fuel injectors.

NOTE: Lubricate the new fuel injector O-ring seals with clean engine oil prior to installation.

Using new O-ring seals, install the fuel injectors.
6. Install the fuel rail and the 4 fuel rail stud bolts.
^ Tighten to 10 Nm (89 inch lbs.).