| : | May 18, 2005 |
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| Removal of the intake manifold on early vehicles will involve the partial dismantling of the fuel rail and the removal of the purge valve and mounting bracket. Once removed, it will also be necessary to remove some excess material from the intake manifold, see 'installation' steps 1 and 2. |
| . | Disconnect the battery ground cable. |
| . | Secure the hood in the service position.
|
| . | Remove the engine cover. |
| . | Remove the air intake resonator. |
| . | Disconnect the throttle body electrical
connector. ![]() |
| . | Disconnect the intake manifold coolant hose.
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| . | Disconnect the throttle body coolant hose.
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| . |
Disconnect the crankcase vent hose. ![]() |
| . | Remove the RH crankcase vent hose. ![]() |
| . | Disconnect the EGR valve electrical connector.
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| . | Disconnect the EGR valve feed pipe.
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| . | Disconnect the intake manifold vacuum pipe
assembly. ![]() |
| . | Disconnect the intake manifold tuning valve
electrical connector. ![]() |
| . | Release the purge line from the intake manifold.
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| . | Release the coil wiring harness.
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| . | Disconnect the 6 coil electrical connectors. |
| . |
:
Remove the 2 rear ignition coils.
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| . | Disconnect the HT leads at the sparking plugs.
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| . | Position the engine wiring harness aside for
access. ![]() |
| . | Remove the 8 intake manifold bolts. ![]() |
| . |
:
Release the intake manifold wiring harness clip. ![]() |
| . |
Using the special tool, disconnect the fuel line.
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| . |
:
Release and then remove the intake manifold.
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| . |
:
Remove the throttle body.
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| . | Disconnect the EGR valve vacuum hose.
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| . | Remove the EGR valve.
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| . | Remove the remaining ignition coils.
|
| . | Remove the HT leads.
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| . | Remove the intake manifold tuning valve.
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| . |
Early vehicles only: Remove the center casting lug. ![]() |
| . | Early vehicles only: Remove excess material from
the outside edges of the 6 intake manifold flange faces; file to within 2
mm of the gasket edge. ![]() |
| . | Early vehicles only: Install the fuel rail and
injectors.
|
| . | Install the intake manifold tuning valve.
|
| . | Secure the HT leads to the intake manifold with clips. |
| . |
:
Install the 4 ignition coils.
|
| . | Install the EGR valve.
|
| . | Connect the vacuum hose to the EGR valve. |
| . | Connect the EGR vacuum hose to the intake
manifold.
|
| . | Install the throttle body.
|
| . | Install the throttle body coolant hose.
|
| . | Secure the wiring harness to the intake
manifold.
|
| . |
:
:
Install the intake manifold.
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| . | Install the remaining ignition coils.
|
| . | Connect the ignition coil electrical connectors. |
| . | Connect the fuel line to the fuel rail.
|
| . | Secure the coil wiring harness.
|
| . | Connect the intake manifold tuning valve electrical connector. |
| . | Connect the vacuum pipe to the inlet manifold. |
| . | Secure the purge line to the intake manifold.
|
| . | Connect the crankcase vent hose.
|
| . | Connect the intake manifold coolant hose.
|
| . | Install the air intake resonator. |
| . | Install the engine cover. |
| . | Connect the hood support struts. |
| . | Connect the battery ground cable. |
| . | Check and top-up the coolant. |