Removal and Replacement

Intake Manifold






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












EGR System Module-to-Exhaust Manifold Tube, Knock Sensor (KS) Electrical Connector, Engine Wiring Harness Retainers and 4 LH Fuel Injector Electrical Connectors












Crankcase Ventilation Tube, Heater Coolant Hose and 4 RH Fuel Injector Electrical Connectors










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. Disconnect the fuel supply tube quick connect coupling.

3. Drain the cooling system.

4. Remove the 8 ignition coils.

5. Remove the generator.

6. Remove the EGR system module-to-exhaust manifold tube.

7. Disconnect the EGR system module electrical connector.

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

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

10. Disconnect the heater coolant hose and position aside.

11. Disconnect the 8 fuel injector electrical connectors.

12. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector and EVAP tube quick connect fitting.

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

14. Disconnect the brake booster vacuum hose.

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





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

17. Remove the thermostat.

18. Remove the 9 intake manifold bolts.

19. Remove the intake manifold 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 fuel supply tube quick connect coupling.

7. Connect the brake booster vacuum hose.

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

9. Connect the EVAP canister purge valve electrical connector and the EVAP tube quick connect fitting.

10. Connect the 8 fuel injector electrical connectors.

11. Connect the heater coolant hose.

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

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

14. Connect the EGR system module electrical connector.

15. Install the EGR system module-to-exhaust manifold tube.
- Tighten to 40 Nm (30 lb-ft).

16. Install the 8 ignition coils.

17. Install the generator.

18. Connect the battery ground cable.

19. Fill and bleed the engine cooling system.