Tools Required

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.




1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Loosen the clamp at the air cleaner assembly and throttle body assembly.
3. Remove the attachment bolts from the outlet resonator/duct assembly to support bracket.
4. Remove the outlet resonator/duct assembly.



5. Remove the resonator outlet duct assembly bracket from the manifold.

Caution: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.




6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
7. Disconnect SA9127E , or equivalent and J 44095 , or equivalent, after the pressure has been relieved.
8. Disconnect the fuel transfer line at the quick connect from the fuel line using J 37088-A , or equivalent blue tool.



9. Disconnect the electrical harness attachment from the manifold and position harness away from the manifold.



10. Disconnect the attachment of the purge solenoid and line from the rear of manifold.
11. Disconnect the brake booster line from the intake manifold.
12. Disconnect the fuel injector and intake manifold control solenoid connectors.



13. Remove the PCV fresh air hose at throttle body.
14. Remove the throttle body bolts from the throttle body.
15. Remove the throttle body cooling hose bracket bolts.
16. With the coolant lines connected to throttle body, lay the throttle body assembly over the mast cylinder.




Important: To remove the 5 upper manifold bolts, use a 1/4 inch drive T-30 TORX and long 1/4 inch drive extension.

17. Remove the upper manifold to spacer plate bolts.



18. Remove the lower intake manifold bolt near the throttle body.
19. Remove the intake manifold assembly.



20. Remove the lower intake manifold spacer plate bolts.



21. Remove the intake spacer plate.
22. Seals are re-usable if not damaged. If O-ring seals re being replaced, remove seals from both sides.



23. The intake spacer plate has O-ring seals on both sides.
24. Clean the spacer plate bolt holes and bolts. Remove all thread locked material.

1. Transfer all components to the new intake manifold.
2. Install new O-rings to spacer assembly, if necessary.



3. Install the intake manifold spacer plate.

Notice: Refer to Fastener Notice in the Preface section.

Important: Do not over torque the intake manifold spacer plate bolts.

4. Install the 12 intake manifold saver plate bolts. Apply LOCTITE® 242 threadlocker, or equivalent, to the bolts.

Tighten
Tighten the bolts to 16 N·m (11 lb ft).





Important: Do not over torque the intake manifold bolts.

5. Install the intake manifold assembly into position.
6. Install the 5 intake manifold bolts.

Tighten
Tighten the bolts to 7.5 N·m (66 lb in).




7. Install the throttle body gasket.
8. Install the throttle body assembly bolts.

Tighten
Tighten the throttle body-to-intake manifold bolts to 7.5 N·m (66 lb in).

9. Connect the PCV fresh air hose at the throttle body.
10. Install the outlet resonator duct assembly bracket to the manifold and tighten nuts.

Tighten
Tighten the outlet resonator duct nuts to 5 N·m (44 lb in).




11. Connect the intake manifold control solenoid and injector harnesses.
12. Connect the electrical harness to the intake bracket near the intake manifold runner control solenoid.
13. Connect the brake vacuum hose to manifold.

Important: An audible click noise can be heard when the fuel line is installed. Slightly pull rearward on line to assure the connection is fully seated.

14. Connect the fuel line to the fuel transfer line.
15. Connect the purge solenoid and line to intake manifold.



16. Attach the electrical harness to rear of manifold.



17. Install the outlet resonator duct assembly into position and tighten clamp at the throttle body assembly.
18. Position the outlet resonator duct assembly to support bracket and install bolts.

Tighten
Tighten the outlet resonator duct-to-bracket nuts to 10 N·m (89 lb in).

19. Tighten the clamp at the air cleaner assembly.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.