1. Remove any remaining gasket and/or gasket material from the following:

•	Throttle body

•	Intake manifold

2. Clean the following intake manifold areas in solvent.

•	Intake manifold gasket sealing areas

•	Intake manifold passages

•	Brake booster hose passage

•	Evaporative emission (EVAP) solenoid passage

•	Positive crankcase ventilation (PCV) vacuum hose passages

•	Barometric pressure (BARO) sensor passage

Caution: Refer to Safety Glasses Caution in the Preface section.

3. Dry the upper intake manifold and throttle body with compressed air.

1. Inspect the upper intake manifold for the following conditions:

•	Damage, debris or restrictions to the BARO sensor mounting port

•	Damage, debris or restrictions to the brake vacuum booster hose port

•	Damage to the throttle body bolt holes

•	Damage, debris or restrictions to the PCV system hose ports




2. Inspect the upper intake manifold for the following conditions:

•	Damage to the intake manifold bolt bosses

•	Damage to the EVAP purge solenoid mounting boss

•	Damage, debris or restrictions to the EVAP purge solenoid port

•	Damage, debris or restrictions in the vacuum passage




3. Inspect the upper intake manifold for the following conditions:

•	Damage, debris or restrictions to the intake manifold opening cover port (1)

•	Damage to the intake manifold opening cover




4. Inspect the upper intake manifold for the following conditions:

•	Gouges or damage to the upper intake manifold sealing surfaces (1)

•	Damage to the gasket sealing surface (2) for the throttle body




5. Inspect the upper intake manifold sealing surface for warpage.

5.1.	Locate a straight edge across the upper-to-lower intake manifold sealing surface.

5.2.	Insert a feeler gage between the upper intake manifold and the straight edge. An upper intake manifold with warpage in excess of 0.05 mm (0.020 in) must be replaced.

6. Repair or replace the upper intake manifold as necessary.

1. Remove any remaining gasket and/or gasket material from the following:

•	Upper-to-lower intake manifold sealing surface

•	Cylinder head-to-lower intake manifold sealing surface

2. Clean the following intake manifold areas in solvent.

•	Intake manifold gasket sealing surfaces

•	Intake manifold passages

Caution: Refer to Safety Glasses Caution in the Preface section.

3. Dry the intake manifold with compressed air.

1. Inspect the lower intake manifold for the following conditions:

•	Damage, debris or restrictions to the lower intake manifold ports

•	Damage to the fuel rail mounting bolt holes

•	Damage to the fuel rail




2. Inspect the lower intake manifold for the following conditions:

•	Gouges or damage to the intake manifold sealing surfaces

•	Damage to the lower intake manifold bolt bosses

•	Damage to the fuel injector ports




3. Inspect the lower intake manifold sealing surfaces for warpage.

3.1.	Locate a straight edge across the lower intake manifold sealing surfaces.

3.2.	Insert a feeler gage between the lower intake manifold and the straight edge. A lower intake manifold with warpage in excess of 0.5 mm (0.020 in) must be replaced.

4. Repair or replace the lower intake manifold as necessary.

Intake Manifold Cleaning and Inspection LY7

1. Remove any remaining gasket and/or gasket material from the following:

•	Throttle body

•	Intake manifold

2. Clean the following intake manifold areas in solvent.

•	Intake manifold gasket sealing areas

•	Intake manifold passages

•	Brake booster hose passage

•	Evaporative emission (EVAP) solenoid passage

•	Positive crankcase ventilation (PCV) vacuum hose passages

•	Barometric pressure (BARO) sensor passage

Warning: Refer to Safety Glasses Warning in the Preface section.

3. Dry the upper intake manifold and throttle body with compressed air.

1. Inspect the upper intake manifold for the following conditions:

•	Damage, debris or restrictions to the BARO sensor mounting port

•	Damage, debris or restrictions to the brake vacuum booster hose port

•	Damage to the throttle body bolt holes

•	Damage, debris or restrictions to the PCV system hose ports




2. Inspect the upper intake manifold for the following conditions:

•	Damage to the intake manifold bolt bosses

•	Damage to the EVAP purge solenoid mounting boss

•	Damage, debris or restrictions to the EVAP purge solenoid port

•	Damage, debris or restrictions in the vacuum passage




3. Inspect the upper intake manifold for the following conditions:

•	Damage, debris or restrictions to the intake manifold opening cover port (1)

•	Damage to the intake manifold opening cover




4. Inspect the upper intake manifold for the following conditions:

•	Gouges or damage to the upper intake manifold sealing surfaces (1)

•	Damage to the gasket sealing surface (2) for the throttle body




5. Inspect the upper intake manifold sealing surface for warpage.

5.1.	Locate a straight edge across the upper-to-lower intake manifold sealing surface.

5.2.	Insert a feeler gage between the upper intake manifold and the straight edge. An upper intake manifold with warpage in excess of 0.05 mm (0.020 in) must be replaced.

6. Repair or replace the upper intake manifold as necessary.

1. Remove any remaining gasket and/or gasket material from the following:

•	Upper-to-lower intake manifold sealing surface

•	Cylinder head-to-lower intake manifold sealing surface

2. Clean the following intake manifold areas in solvent.

•	Intake manifold gasket sealing surfaces

•	Intake manifold passages

Warning: Refer to Safety Glasses Warning in the Preface section.

3. Dry the intake manifold with compressed air.

1. Inspect the lower intake manifold for the following conditions:

•	Damage, debris or restrictions to the lower intake manifold ports

•	Damage to the fuel rail mounting bolt holes

•	Damage to the fuel rail




2. Inspect the lower intake manifold for the following conditions:

•	Gouges or damage to the intake manifold sealing surfaces

•	Damage to the lower intake manifold bolt bosses

•	Damage to the fuel injector ports




3. Inspect the lower intake manifold sealing surfaces for warpage.

3.1.	Locate a straight edge across the lower intake manifold sealing surfaces.

3.2.	Insert a feeler gage between the lower intake manifold and the straight edge. A lower intake manifold with warpage in excess of 0.5 mm (0.020 in) must be replaced.

4. Repair or replace the lower intake manifold as necessary.

Intake Manifold Cleaning and Inspection LCS

1. Install the fuel injector rail.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the fuel injector rail bolts and tighten to 10 N·m (89 lb in).



3. Install the fuel injector wiring harness connector.

1. Install the intake manifold opening cover.
2. Install the intake manifold opening cover bolts and tighten to 10 N·m (89 lb in).



3. Install the barometric pressure (BARO) sensor.
4. Install the BARO sensor bolt and tighten to 10 N·m (89 lb in).



5. Install the NEW throttle body gasket.
6. Install the throttle body.
7. Install the throttle body bolts and tighten to 10 N·m (89 lb in).



8. Install the fuel rail support bracket.
9. Install the fuel rail support bracket bolt and tighten to 10 N·m (89 lb in).

Note: Do not reuse the upper-to-lower intake manifold gasket and the intake manifold-to-cylinder head sealing gaskets.

1. Install the NEW upper-to-lower intake manifold gaskets.



2. Install the upper intake manifold to the lower intake manifold.



3. Install the fuel injector wiring harness bracket bolts to the upper intake manifold and tighten to 10 N·m (89 lb in).



4. Install the upper-to-lower intake manifold bolts and tighten to 23 N·m (17 lb ft).