Intake Manifold Assembly

Intake Manifold Assembly























Disassembly
1. Remove the heater hose.
2. Remove the supercharger (SC) bubbler hose.
3. Remove the upper and lower SC bypass actuator vacuum tubes.
4. Remove the 2 bolts and the EGR system module.
^ Discard the gasket.
5. Disconnect the vacuum tube from the fuel rail and pressure temperature sensor.
6. Remove the 4 fuel rail bolts.
^ Remove the fuel rail and injectors as an assembly.

7. NOTE: The fuel injector clip can be reused if it is not damaged during removal.

Remove the clips and the fuel injectors from the fuel rail.

8. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse the O-ring seals.

Remove and discard the fuel injector O-ring seals.
9. Remove the 10 bolts and the SC.
^ Discard the gasket.
10. Remove the vacuum tube.
11. Remove the intake air temperature 2 (IAT2) sensor.
12. Remove the 5 bolts and the charge air cooler (CAC) tube assembly.
^ Discard the gasket.
13. Remove the 2 CAC coolant connector tubes.
^ Discard the O-ring seals.
14. Remove the 13 bolts and the lower intake manifold cover.
^ Discard the gasket.
15. Remove the 10 bolts, the 2 CAC rail supports and the CAC.

Assembly

1. NOTE: Apply Threadlock(R) and sealer to the CAC bolts prior to installation.

Position the CAC, the 2 CAC rail supports and install the bolts.
^ Tighten the bolts in the sequence shown in 2 stages:
^ Stage 1: Tighten to 2 Nm (18 lb-in).
^ Stage 2: Tighten to 10 Nm (89 lb-in).





2. Install a new gasket, the lower intake manifold cover and the 13 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





3. NOTE: Apply clean engine coolant to the new CAC coolant connector tube O-ring seals.

Install new O-ring seals on the CAC coolant connector tubes.
^ Install the CAC coolant connector tubes.
4. Install a new gasket, the CAC coolant tube assembly and the 5 bolts.
^ Tighten to 10 Nm (89 lb-in).
5. Install the IAT2 sensor.
^ Tighten to 15 Nm (11 lb-ft).
6. Install the vacuum tube.
7. Install a new gasket, the SC and the 10 bolts.
^ Tighten the bolts in the sequence shown in 2 stages:
^ Tighten to 5 Nm (44 lb-in).
^ Tighten to 25 Nm (18 lb-ft).





8. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install new O-ring seals on each of the fuel injectors.
9. Install the fuel injectors onto the fuel rail and install the locking clips.
10. Install the fuel rail and fuel injector assembly onto the intake manifold.
11. Install the 4 fuel rail bolts.
^ Tighten to 10 Nm (89 lb-in).
12. Connect the vacuum tube to the fuel rail and pressure temperature sensor.
13. Install a new gasket, the EGR system module and the 2 bolts.
^ Tighten to 25 Nm (18 lb-ft).
14. Install the upper and lower SC bypass actuator vacuum tubes.
15. Install the SC bubbler hose.
16. Install the heater hose.