Intake Air Plenum: Service and Repair

Intake Plenum And Runners:

REMOVAL:

1. Disconnect the negative battery cable.
2. Partially drain the cooling system to allow the lower hose at the throttle body to be removed.
3. Remove the throttle, TV (transmission control), and cruise control cables.
4. Remove the cable retaining bracket.
5. Remove the air intake duct.
6. Disconnect the vacuum hoses from the throttle body.
7. Disconnect the coolant hoses.
8. Disconnect the electrical connectors from the TPS and IAC valve.
9. Remove the throttle body bolts.
10. Remove the throttle body assembly.
11. Disconnect the electrical connectors from the injectors, left/right electrical harness attaching nuts and harnesses.
12. Disconnect the power brake vacuum line at the plenum.
13. Remove the runner to plenum bolt attaching the MAP sensor.
14. Remove the MAP sensor and vacuum hoses from the plenum.
15. Remove the remaining runner to plenum bolts.
16. Lift the plenum and disconnect the MAT sensor electrical connector.
17. Remove the plenum and gaskets. Discard the gaskets.
18. Remove the left side runner to manifold bolts.
19. Remove the PCV valve and hose.
20. Remove the right side runner to manifold bolts.
21. Remove the EGR solenoid.
22. Remove the left and right side manifold to runner bolts.
23. Remove the left and right side runners and gaskets. Discard the gaskets.

INSTALLATION:

CAUTION: Use care when cleaning gasket material from machined aluminum surfaces. Sharp tools may damage sealing surfaces.

1. Install new gaskets on the runners and intake manifold.
2. Install the left and right side runners.
3. Install the left and right side manifold to runner bolts, and tighten to 34 Nm (25 lb.ft).
4. Install the EGR solenoid.
5. Install the right and left hand runner to manifold bolts.
^ Finger tighten only.
6. Support the plenum above the runners, connect the MAT sensor electrical connector, then lower the plenum into position.
^ Start a few bolts to hold the plenum in position.
7. Connect the vacuum hoses and MAP sensor.
8. Install the remaining runner to plenum bolts, and tighten to 34 Nm (25 lb.ft) starting in the center and working outward.
9. Connect the PCV valve and hose.
10. Install the power brake vacuum line to the fitting on the plenum, and tighten to 12.2 Nm (108 lb.in).
11. Install the left/right injector electrical harnesses, attaching nuts, and electrical connectors to the injectors.
12. Install the throttle body with a new gasket.
13. Install the throttle body attaching bolts, and tighten to 24 Nm (18 lb.ft).
14. Connect the electrical connectors to the TPS and IAC valve.
15. Connect the coolant hoses.
16. Connect the vacuum hoses.
17. Install the air intake duct.
18. Install the throttle cable bracket.
19. Install the throttle, T.V., and cruise control cables.
20. Refill the radiator.
21. Connect the negative battery cable.