Intake Manifold Assembly - Disassembly and Assembly

Intake Manifold Assembly







Evaporative Emission (EVAP) Purge Valve, Fuel Rail and Fuel Injectors











Intake Manifold Vacuum Tube, Throttle Body (TB) and Intake Manifold









Disassembly

1. Remove the bolt and disconnect the quick connect coupling and remove the Evaporative Emission (EVAP) purge valve assembly.

2. Remove the 4 bolts and the fuel rail.

3. Remove the 8 fuel injector-to-fuel rail locking clips and separate the 8 fuel injectors from the fuel rail.
- Discard the 2 O-ring seals from each fuel injector.

4. Remove the vacuum tube assembly from the intake manifold.

5. Remove the 2 bolts and the PCV fitting.

6. Remove the 4 bolts, the vibration damper and the Throttle Body (TB).

Assembly

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

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

Install the PCV fitting and the 2 bolts.

- Tighten to 6 Nm (53 lb-in).

2. Install the vacuum tube assembly onto the intake manifold and position the clamp.

3. Install the TB, vibration damper and tighten the 4 bolts in 2 stages.
- Stage 1: Tighten to 9 Nm (80 lb-in).

- Stage 2: Tighten an additional 90 degrees.

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

Install 16 new O-ring seals on each of the fuel injectors.

5. Assemble the 8 fuel injectors onto the fuel rail and install the 8 locking clips.

6. Install the fuel rail and fuel injector as an assembly onto the intake manifold.

7. Install the 4 fuel rail bolts.
- Tighten to 10 Nm (89 lb-in).

8. Position the Evaporative Emission (EVAP) purge valve assembly and connect the quick connect coupling and install the bolt.
- Tighten to 10 Nm (89 lb-in).