Removal and Replacement

Intake Manifold - 4.6L (2V)







Crankcase Ventilation Tube, Heater Coolant Hose and Upper Radiator Coolant Hose










Generator Support Bracket and Transmission Fluid Filler Tube Support Bracket Bolt










Electrical Connectors, Vacuum Tube and Evaporative Emission (EVAP) Purge Valve Tube Quick Connect Coupling










EGR System Module-To-Exhaust Manifold Tube, EGR System Module and Throttle Body (TB)










Thermostat Housing, Thermostat, Intake Manifold and Gaskets









Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Disconnect the battery ground cable.

2. Remove the engine cover.

3. Remove the Air Cleaner (ACL) assembly and the ACL outlet pipe.

4. Drain the cooling system.

5. Disconnect the fuel supply tube quick connect coupling.

6. Disconnect the quick connect couplings and remove the PCV tube.

7. Remove the front transmission fluid filler tube support bracket bolt.

8. Remove bolt and position the transmission fluid filler tube aside.





9. If equipped, disconnect the auxiliary heater hoses and position them aside.





10. Disconnect the Electronic Throttle Control (ETC) and the PCV heater element electrical connectors and the wiring harness retainer.

11. Remove the 4 Throttle Body (TB) bolts, the TB and TB gasket.
- Discard the TB gasket.

12. Disconnect the electrical connector and the Evaporative Emission (EVAP) canister-to-EVAP canister purge valve tube quick connect coupling from the EVAP purge valve.

13. Disconnect the brake booster vacuum hose from the intake manifold.

14. Disconnect the EGR system module vacuum connector and position the vacuum tube assembly aside.

15. Disconnect the EGR system module electrical connector.

16. Disconnect the upper and lower fittings and remove the exhaust manifold-to-EGR system module tube.

17. Remove the 2 bolts and the EGR system module.
- Discard the EGR system module gasket.

18. Remove the 8 ignition coils.

19. Remove the 4 bolts and the generator support bracket.

20. Disconnect the heater coolant hose and position aside.

21. Disconnect the 8 fuel injector electrical connectors.

22. Disconnect the Knock Sensor (KS) electrical connector, electrical connector retainer and the 2 engine wiring harness retainers from the rear of the intake manifold.





23. Disconnect the upper radiator coolant hose and position aside.

24. Remove the 2 thermostat housing bolts and the thermostat housing and discard the O-ring seal.

25. Remove the thermostat.

26. Remove the 9 intake manifold bolts.

27. Remove the intake manifold through the passenger compartment and discard the RH and LH intake manifold gaskets.

Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover. Follow the directions on the packaging.

2. 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.

Install the intake manifold in the following sequence.

1. Position the new intake manifold gaskets.

2. Position the intake manifold.

3. Loosely install the 9 intake manifold bolts.

3. Tighten the 9 intake manifold bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





4. Install the thermostat, a new thermostat housing O-ring seal, the thermostat housing and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).

5. Connect the upper radiator coolant hose.

6. Connect the KS electrical connector, electrical connector retainer and the 2 engine wiring harness retainers to the rear of the intake manifold.





7. Connect the 8 fuel injector electrical connectors.

8. Connect the heater coolant hose.

9. Position the generator support bracket and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).

10. Install the 8 ignition coils.

11. NOTE: The EGR valve sealing surfaces are soft metals.

Carefully clean both sealing surfaces and install a new EGR system module gasket with the side with the raised ring facing the intake manifold.





12. Install the EGR system module and the 2 bolts.
- Tighten the 2 bolts in 2 stages.
- Stage 1: Tighten to 25 Nm (18 lb-ft).

- Stage 2: Tighten an additional 90 degrees.

13. Position the exhaust manifold-to-EGR system module tube and connect the upper and lower fittings.
- Tighten to 42 Nm (31 lb-ft).

14. Position the vacuum tube assembly and connect the EGR system module vacuum connector.

15. Connect the EGR system module electrical connector.

16. Connect the brake booster vacuum hose to the intake manifold.

17. Connect the electrical connector and the EVAP canister-to-EVAP canister purge valve tube quick connect coupling to the EVAP purge valve.

18. Using a new TB gasket, position the TB and install the 4 bolts in 2 stages.
- Stage 1: Tighten to 9 Nm (80 lb-in).

- Stage 2: Tighten an additional 90 degrees (one-fourth turn).

19. Connect the ETC and the PCV heater element electrical connectors and the wiring harness retainer.

20. If equipped, connect the auxiliary heater hose quick connect couplings.





21. Position the transmission fluid filler tube and install the bolt.
- Tighten to 10 Nm (89 lb-in).





22. Install the front transmission fluid filler tube support bracket bolt.
- To install, tighten to 28 Nm (21 lb-ft).

23. Position the PCV tube and connect the quick connect couplings.

24. Connect the fuel supply tube quick connect coupling.

25. Install the engine cover.

26. Install the ACL assembly and the ACL outlet pipe.

27. Connect the battery ground cable.

28. Fill and bleed the engine cooling system.