Intake Manifold: Service and Repair

Intake Manifold - Boss(R) 302





Hoses and Supports










Wiring Harness and Emission tubes










Fuel Rail Insulators, Intake Manifold and Gaskets

NOTE:

NOTE:









Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Release the fuel system pressure.

2. Remove the 4 nuts and the strut tower cross brace.





3. Remove the 3 nuts, the pin-type retainer and the 2 engine shields.





4. Remove the Air Cleaner (ACL) outlet pipe.

5. Disconnect the Throttle Body (TB) electrical connector.

6. Disconnect the Evaporative Emission (EVAP) tube from the canister purge valve.
- Disconnect the EVAP (Evaporative Emission) canister purge valve electrical connector and wiring harness retainer.






7. Remove the crankcase ventilation tube.

8. Disconnect the fuel supply tube.

9. Disconnect the vacuum tube from the intake manifold.

10. Position the heater hoses aside.

11. Remove the 2 nuts and the LH heater hose support.
- Position the vacuum tube assembly aside.


12. Remove the 2 nuts and the RH heater hose support.

13. Remove the LH and RH fuel rail insulators.

14. Disconnect the 8 fuel injector electrical connectors.

15. Detach the 2 wiring harness retainers from the rear of the intake manifold.

16. NOTE: It is not necessary to remove the fuel rail from the intake manifold assembly.
Remove the 4 fuel rail bolts.


17. Loosen the 6 bolts and remove the intake manifold.
- Discard the gaskets.


18. If necessary, remove the 2 insulators from the engine.

Installation

1. If removed, install the 2 insulators on the engine.

2. 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 if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

NOTE: Fuel rail removed from graphic for clarity.

Using new gaskets, install the intake manifold.
- Tighten the 6 intake manifold bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.






3. Install the 4 fuel rail bolts.
- Tighten in the sequence shown in 3 stages.
- Stage 1: Hand tighten.

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

- Stage 2: Tighten an additional 90 degrees.






4. Attach the 2 wiring harness retainers to the rear of the intake manifold.

5. Connect the 8 fuel injector electrical connectors.

6. Install the LH and RH fuel rail insulators.

7. Install the RH heater hose support and the 2 nuts.
- Tighten to 7 Nm (62 lb-in).


8. Install the vacuum tube assembly, the LH heater hose support and the 2 nuts.
- Tighten to 7 Nm (62 lb-in).


9. Position the heater hoses.

10. Connect the vacuum tube to the intake manifold.

11. Connect the fuel supply tube.

12. Install the crankcase ventilation tube.

13. Connect the EVAP (Evaporative Emission) tube to the canister purge valve.
- Connect the EVAP (Evaporative Emission) canister purge valve electrical connector and wiring harness retainer.






14. Connect the TB (Throttle Body) electrical connector.

15. Install the Air Cleaner (ACL) outlet pipe.

16. Install the 2 engine shields, the 3 nuts and the pin-type retainer.
- Tighten to 7 Nm (62 lb-in).






17. Install the strut tower cross brace and the 4 nuts.
- Tighten to 35 Nm (26 lb-ft).