For 1990-2009 cars only
Removal Procedure
- Remove the cross car brace. Refer to Cross Vehicle Brace Replacement.
- Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
- Remove the positive crankcase ventilation (PCV) dirty air tube from the camshaft cover. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
- Remove the PCV fresh air tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
- Remove the sight shield bracket nuts.
- Remove the sight shield bracket.
- Disconnect the left side fuel injector electrical connectors (1) from the fuel injectors (2).
- Disconnect the right side fuel injector electrical connectors (1) from the fuel injectors (2).
- Disconnect the evaporative emission (EVAP) purge valve line (2) and electrical connector (1).
- Remove the EVAP line from the retaining feature (2) at the rear of the right head. Position the line aside.
- Relieve the fuel system pressure. Refer to Fuel Pressure Relief
- Disconnect the fuel line from the fuel rail (1). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service.
- Remove the fuel line from the retainer at the rear of the right head.
- Remove the fasteners attaching the fuel rail to the intake manifold.
- Lift the entire fuel rail and injector assembly from the intake manifold.
- Loosen the plenum duct clamp (1) at the front of the intake manifold.
- Loosen the bolts attaching the intake manifold to the cylinder heads.
- Remove the intake manifold by using an upward lifting motion at the rear of the manifold assembly.
- Inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection.
Installation Procedure
- Transfer the necessary parts when replacing the intake manifold. Refer to Intake Manifold Disassemble and Intake Manifold Assemble.
- Lightly grease the inside edge of the rubber plenum duct.
- Ensure that the NEW gaskets are installed to the intake manifold.
- Place the intake manifold in position.
- Position the front of the intake manifold into the plenum duct.
- Position the rear of the intake manifold downward onto the cylinder heads.
- Loosely install the 10 bolts attaching the intake manifold to the cylinder heads.
- Tighten the intake manifold bolts in sequence (1-10) to 10 N·m (89 lb in).
- Ensure that the plenum duct is fully attached to the front of the intake manifold and tighten to 2.25 N·m (20 lb in).
- Lubricate the intake manifold fuel injector bores with light mineral oil, clean engine oil or equivalent. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
- Install the entire fuel rail and injector assembly into the intake manifold by pressing the fuel rail and injector simultaneously into the correct position.
- Install the bolts attaching the fuel rail to the intake manifold and tighten to 10 N·m (89 lb in).
- Install the fuel line to the retainer at the rear of the right head.
- Connect the fuel line to the fuel rail (1). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service.
- Install the EVAP purge valve line to the retainer (2) at the rear of the right head.
- Install the EVAP purge valve line (2) and electrical connector (1).
- Connect the right side fuel injector electrical connectors (1) to the fuel injectors (2).
- Connect the left side fuel injector electrical connectors (1) to the fuel injectors (2).
- Install the sight shield bracket.
- Install the sight shield bracket nuts and tighten to 10 N·m (89 lb in).
- Install the PCV fresh air tube to the engine.
- Install the PCV dirty air tube to the engine.
- Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
- Install the cross car brace. Refer to Cross Vehicle Brace Replacement.
Caution: Refer to Fastener Caution in the Preface section.
Note: DO NOT force the injectors into position.
