Intake Plenum Replacement

INTAKE PLENUM REPLACEMENT (IN-VEHICLE)

REMOVAL





1. Disconnect negative battery cable.
2. Remove air cleaner hose assembly from the throttle body.





3. Disconnect throttle body electrical connection.





4. Remove electrical connection and vacuum hoses from intake plenum switch over valve solenoid.
5. Remove vacuum hose from fuel pressure regulator.





6. Remove front intake plenum hose clamps, pipe bolts, and plenum bolts.
7. Lift plenum and remove throttle body heater hoses.

NOTICE: Mask off the ports to the intake manifold. Severe damage may result if foreign objects enter the engine.

8. Remove intake plenum.

NOTICE: It is not necessary to remove the rear intake runner.

9. Remove front intake runner.





10. Remove throttle body nut and throttle body assembly.


INSTALLATION





1. Install throttle body gasket to plenum.
2. Install throttle body to plenum.
3. Install throttle body nuts.
Torque:
Throttle Body Nut: 8 Nm (71 inch lbs.)





4. Attach heater and vent hose to throttle body.
5. Install intake plenum and intake plenum bolts. Finger tighten bolts.
6. Install EGR pipe bolts.
Torque:
EGR Pipe Bolts: 25 Nm (19 ft. lbs.)
7. Install intake plenum bolts.
Torque:
Intake Plenum Bolts: 8 Nm (71 inch lbs.)





8. Install front manifold runner and tighten clamps.
9. Install intake runner bolts.
Torque:
Intake Manifold Runner Bolts: 8 Nm (71 inch lbs.)
10. Connect negative battery cable.
Torque:
Battery Terminal Bolts: 17 Nm (13 ft. lbs.)