Overhaul

Intake Manifold Assembly





Intake Manifold Assembly (View 1 of 3)










Intake Manifold Assembly (View 2 of 3)










Intake Manifold Assembly (View 3 of 3)









Disassembly

1. Remove the heater hose.

2. Remove the Supercharger (SC) bubbler hose.

3. Remove the upper and lower SC (Supercharger) bypass actuator vacuum tubes.

4. Remove the 2 bolts and the EGR system module.
- Discard the gasket.


5. Disconnect the vacuum tube from the fuel rail and pressure temperature sensor.

6. Remove the 4 fuel rail bolts.
- Remove the fuel rail and injectors as an assembly.


7. Remove the 8 fuel injector clips and the 8 fuel injectors from the fuel rail.
- Discard the 8 fuel injector clips.


8. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse the O-ring seals.

Remove and discard the 16 fuel injector O-ring seals.


9. Remove the 10 bolts and the SC (Supercharger).
- Discard the gasket.


10. Remove the vacuum tube.

11. Remove the Intake Air Temperature 2 (IAT2) sensor.

12. Remove the 5 bolts and the Charge Air Cooler (CAC) tube assembly.
- Discard the gasket.


13. Remove the 2 CAC (Charge Air Cooler) coolant connector tubes.
- Discard the O-ring seals.


14. Remove the 13 bolts and the lower intake manifold cover.
- Discard the gasket.


15. Remove the 10 bolts, the 2 CAC (Charge Air Cooler) rail supports and the CAC (Charge Air Cooler).

Assembly

1. 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.

NOTE: Apply threadlock and sealer to the CAC (Charge Air Cooler) bolts prior to installation.

Position the CAC (Charge Air Cooler) , the 2 CAC (Charge Air Cooler) rail supports and install the 10 bolts.
- Tighten the bolts in the sequence shown in 2 stages:
- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 10 Nm (89 lb-in).






2. Install a new gasket, the lower intake manifold cover and the 13 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






3. NOTE: Apply clean engine coolant to the new CAC (Charge Air Cooler) coolant connector tube O-ring seals.
Install new O-ring seals on the CAC (Charge Air Cooler) coolant connector tubes.

- Install the CAC (Charge Air Cooler) coolant connector tubes.


4. Install a new gasket, the CAC (Charge Air Cooler) coolant tube assembly and the 5 bolts.
- Tighten to 10 Nm (89 lb-in).


5. Install the IAT2 (Intake Air Temperature 2) sensor.
- Tighten to 15 Nm (133 lb-in).


6. Install the vacuum tube.

7. Install a new gasket, the SC (Supercharger) and the 10 bolts.
- Tighten the bolts in the sequence shown in 2 stages:
- Tighten to 5 Nm (44 lb-in).

- Tighten to 25 Nm (18 lb-ft).






8. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install new O-ring seals on each of the fuel injectors.


9. Install the 8 fuel injectors onto the fuel rail and install 8 new fuel injector clips.

10. Install the fuel rail and fuel injector assembly onto the intake manifold.

11. Install the 4 fuel rail bolts.
- Tighten to 10 Nm (89 lb-in).


12. Connect the vacuum tube to the fuel rail and pressure temperature sensor.

13. Install a new gasket, the EGR system module and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).


14. Install the upper and lower SC (Supercharger) bypass actuator vacuum tubes.

15. Install the SC (Supercharger) bubbler hose.

16. Install the heater hose.