Removal and Replacement
Intake Manifold
PCV Tube, Body Vacuum Tube Connector, Coolant Heated PCV Fitting Coolant Hoses, Throttle Position (TP) and Electronic Throttle Control (ETC) Electrical Connectors
Throttle Body (TB) and Engine Wiring Harness Retainers
Generator Wiring Harness and Support Bracket, Ignition Coil and Fuel Injector Electrical Connectors
Ignition Coils, Thermostat Housing, Thermostat and Intake Manifold
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. Drain the cooling system.
4. Remove the Air Cleaner (ACL) and the ACL (Air Cleaner) outlet pipe.
5. Disconnect the fuel supply hose quick connect coupling.
6. Disconnect the generator electrical wiring harness retainer and the generator electrical connector.
7. Position the generator B+ protective boot aside and remove the generator B+ nut and terminal and position the generator harness aside.
8. Remove the 3 bolts, the stud bolt and the generator support bracket.
9. Compress and slide the hose clamp and disconnect the coolant hose.
10. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
Disconnect the electronic Electronic Throttle Control (ETC) electrical connector.
11. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
Disconnect the Throttle Position (TP) sensor electrical connector.
12. Disconnect the quick connect couplings and remove the PCV tube.
13. Disconnect the 2 coolant heated PCV fitting coolant hoses and the body vacuum tube connector.
14. Disconnect the brake booster vacuum hose and the Evaporative Emission (EVAP) hose quick connect coupling.
15. Disconnect the electrical connector, remove the bolt and position the EVAP (Evaporative Emission) canister purge valve aside.
16. Remove the 4 bolts and the Throttle Body (TB) and TB (Throttle Body) spacer as an assembly.
- Discard the TB (Throttle Body) spacer gasket.
17. Disconnect the heater coolant hose.
18. Disconnect the 10 fuel injector electrical connectors.
19. Disconnect the 10 ignition coil electrical connectors.
20. Remove the transmission fluid indicator and tube support bracket nut.
21. Remove the transmission fluid level indicator tube support bracket nut and position the tube aside.
22. Disconnect the 2 RH engine wiring harness retainers and position the harness aside.
23. Disconnect the 3 LH engine wiring harness retainers and position the harness aside.
24. Remove the bolt and position the engine wiring harness support bracket aside.
25. Remove the 10 bolts and the 10 ignition coils.
26. Remove the 2 bolts, thermostat housing and thermostat.
- Discard the O-ring seal.
27. Remove the 11 bolts, the intake manifold and the intake manifold gaskets.
- Discard the 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 silicone gasket remover and metal surface prep. 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.
Position new intake manifold gaskets and the intake manifold, and loosely install the 11 bolts.
3. Using a new O-ring seal, install the thermostat.
4. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
Position the thermostat housing and loosely install the 2 bolts.
5. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
6. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.
Position the 10 ignition coils and install the 10 bolts.
- Apply silicone brake caliper grease and dielectric compound to the inside of the coil boots prior to installation.
- Tighten to 6 Nm (53 lb-in).
7. Connect the pushpin retainer to the intake manifold bracket.
8. Position the engine harness and connect the 3 LH engine wiring harness retainers.
9. Position the engine harness and connect the 2 RH engine wiring harness retainers.
10. Position back the transmission fluid level indicator tube and install the nut.
- Tighten to 10 Nm (89 lb-in).
11. Install the transmission fluid indicator and tube support bracket nut.
- Tighten to 28 Nm (21 lb-ft).
12. Connect the 10 ignition coil electrical connectors.
13. Connect the 10 fuel injector electrical connectors.
14. Connect the heater coolant hose.
15. Install a new TB (Throttle Body) spacer gasket and the TB (Throttle Body) and TB (Throttle Body) spacer as an assembly. Tighten the 4 bolts in 2 stages.
- Stage 1: Tighten to 9 Nm (80 lb-in).
- Stage 2: Tighten an additional 90 degrees.
16. Position the EVAP (Evaporative Emission) canister purge valve and install the bolt and the electrical connector.
- Tighten to 10 Nm (89 lb-in).
17. Connect the brake booster vacuum hose and the EVAP (Evaporative Emission) hose quick connect coupling.
18. Connect the 2 coolant heated PCV fitting coolant hoses and the body vacuum tube connector.
19. Position the PCV tube and connect the quick connect couplings.
20. Connect the TP (Throttle Position) sensor electrical connector and wiring harness retainer.
- Push in the red clip.
21. Connect the ETC (Electronic Throttle Control) electrical connector.
- Push in the red clip.
22. Install the upper radiator hose.
23. Position the generator harness and the generator B+ terminal and install the nut and protective boot.
- Tighten to 8 Nm (71 lb-in).
24. Connect the generator electrical wiring harness retainer and the generator electrical connector.
25. Connect the fuel hose quick connect coupling.
26. Install the ACL (Air Cleaner) and the ACL (Air Cleaner) outlet pipe.
27. Install the engine cover.
28. Connect the battery ground cable.
29. Fill the cooling system.