Intake Manifold Replacement (L84)

Single Use Fasteners and Components Intake Manifold Gasket [8x] Throttle Body Gasket Removal Procedure

Intake Manifold Replacement (L84) — figure 1

1. Air Cleaner Outlet Duct Bracket Bolt (1) » Remove
2. Remove engine wiring harness from air cleaner outlet duct bracket.

Intake Manifold Replacement (L84) — figure 2

3. Positive Crankcase Ventilation Fresh Air Tube (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
4. Air Cleaner Outlet Duct Clamp (2) » Loosen [2x]
5. Air Cleaner Outlet Duct (3) » Remove

Intake Manifold Replacement (L84) — figure 3

6. Plenum Front Panel Outer Reinforcement (1) » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation

Intake Manifold Replacement (L84) — figure 4

7. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Disengage — Plastic Collar Quick Connect Fitting Service
8. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Remove and position aside

Intake Manifold Replacement (L84) — figure 5

9. Engine Wiring Harness Connector (1) @ Throttle Body » Disconnect
10. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Remove [2x]
11. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Disconnect
12. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Disconnect

Intake Manifold Replacement (L84) — figure 6

13. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [4x]

Intake Manifold Replacement (L84) — figure 7

14. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [3x]

Intake Manifold Replacement (L84) — figure 8

15. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Disconnect and reposition — Plastic Collar Quick Connect Fitting Service

Intake Manifold Replacement (L84) — figure 9

Note

Some components not shown for graphic clarity.

16. Loosen the 10 intake manifold bolts (1) until the bolts are no longer threaded into the cylinder heads.
17. Move the intake manifold and intake manifold cover (2) forward enough to gain access to the rear engine wiring harness retainers.

Intake Manifold Replacement (L84) — figure 10

18. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [4x]

Intake Manifold Replacement (L84) — figure 11

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

19. Remove the intake manifold and intake manifold cover (1) as an assembly.
20. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.

Intake Manifold Replacement (L84) — figure 12

21. Intake Manifold Cover Bolt (1) » Remove [4x]
22. Intake Manifold Cover (2) » Remove

Intake Manifold Replacement (L84) — figure 13

23. Intake Manifold Gasket (1) » Remove and DISCARD [8x]

Intake Manifold Replacement (L84) — figure 14

24. Throttle Body Bolt (1) » Remove [4x]
25. Throttle Body (2) » Remove
26. Throttle Body Gasket (3) » Remove and DISCARD

Intake Manifold Replacement (L84) — figure 15

27. Manifold Absolute Pressure Sensor Bolt (1) » Remove
28. Manifold Absolute Pressure Sensor (2) » Remove
29. Evaporative Emission Canister Purge Solenoid Valve Bolt (4) » Remove
30. Evaporative Emission Canister Purge Solenoid Valve (3) » Remove Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Warning

Refer to Safety Glasses and Compressed Air Warning. Intake Manifold

Intake Manifold Replacement (L84) — figure 16

1. Clean all sealing surfaces.

2. Dry the intake manifold with compressed air.

3. Inspect the intake manifold cylinder head deck for warpage.

4. Place a straight edge (1) across the intake manifold cylinder head deck surface.

5. Inspect the intake manifold for the following conditions: 5.1. Inspect for loose threaded inserts or studs. 5.2. Inspect for damaged or broken vacuum fitting. 5.3. Inspect the intake manifold assembly for cracks or other damage. 5.4. Inspect for damaged intake manifold gasket sealing surfaces.

6. Position the straight edge (1) across a minimum of two runner port openings and check for warpage using a feeler gage. Engine Mechanical Specifications

7. Inspect the ventilation system passages for restrictions. Installation Procedure

8. Evaporative Emission Canister Purge Solenoid Valve (3) » Install

Caution

Refer to Fastener Caution.

2. Evaporative Emission Canister Purge Solenoid Valve Bolt (4) » Install and tighten — Fastener Specifications

3. Manifold Absolute Pressure Sensor (2) » Install

4. Manifold Absolute Pressure Sensor Bolt (1) » Install and tighten — Fastener Specifications

5. Throttle Body Gasket (3) » Install NEW

6. Throttle Body (2) » Install

7. Throttle Body Bolt (1) » Install and hand tighten [4x]

8. Throttle Body Bolt (1) » Tighten [4x] — Fastener Specifications

9. Intake Manifold Cover (2) » Install

10. Intake Manifold Cover Bolt (1) » Install and hand tighten [4x]

11. Intake Manifold Cover Bolt (1) » Tighten [4x] — Fastener Specifications

12. Remove the covers from the cylinder head passages.

13. Intake Manifold Gasket (1) » Install NEW [8x]

14. Clean all sealing surfaces.

15. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 15.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 15.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 15.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 15.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

16. Position the intake manifold and Intake manifold cover (1) to install harness retainers.

17. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [4x]

18. Move the intake manifold and intake manifold cover (2) into place.

Note

Some components not shown for graphic clarity.

19. Intake Manifold Bolt (1) » Hand tighten [10x]

20. Intake Manifold Bolt (1) » Tighten in sequence [10x] — Fastener Specifications

21. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Install — Plastic Collar Quick Connect Fitting Service

22. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [3x]

23. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [4x]

24. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Connect

25. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Connect

26. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Install [2x]

27. Engine Wiring Harness Connector (1) @ Throttle Body » Connect

28. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Install

29. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Engage — Plastic Collar Quick Connect Fitting Service

30. Plenum Front Panel Outer Reinforcement (1) » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

31. Air Cleaner Outlet Duct (3) » Install

Caution

Refer to Component Fastener Tightening Caution.

32. Air Cleaner Outlet Duct Clamp (2) » Tighten [2x] — Fastener Specifications

33. Positive Crankcase Ventilation Fresh Air Tube (1) » Connect — Plastic Collar Quick Connect Fitting Service

34. Air Cleaner Outlet Duct Bracket Bolt (1) » Install and tighten — Fastener Specifications

35. Install engine wiring harness to air cleaner outlet duct bracket.