Intake Plenum Replacement

TOOLS REQUIRED
^ J-43914 Hose Clamp Pliers

REMOVAL




1. Disconnect negative battery cable.
2. Remove air cleaner and air inlet hose from throttle body.




3. Remove throttle body electrical connector.




4. Remove electrical connector and vacuum hose from intake plenum switchover valve solenoid.
5. Remove vacuum hose from fuel pressure regulator.




6. Remove intake plenum hose clamps using J-43914 hose clamp pliers, and bolts.

IMPORTANT: It is only necessary to remove the front intake runner to remove intake plenum.

7. Remove intake plenum.




8. Remove plenum mounting bolts and EGR pipe connection.
9. Lift plenum and remove throttle body coolant hoses.




10. Remove throttle body nuts.
11. Remove throttle body.


INSTALLATION




1. Install rear manifold runner, if required. Route crankcase hoses under runner. Install heater hose.
2. Route crankcase hoses under runner.
3. Install coolant hose.




4. Install throttle body gasket to plenum.
5. Install throttle body to plenum.
6. Install throttle body nuts.

Torque: 8 N.m (71 in-lbs)

7. Install intake plenum and intake plenum nuts.
8. Attach coolant hoses to throttle body.
9. Install intake plenum nuts.

Torque: 8 N.m (71 in-lbs)




10. Install front manifold runner and tighten clamps.
11. Install intake manifold runner bolts.

Torque: 8 N.m (71 in-lbs)