Registered: May 2008
Location: S.E. Michigan
15) IF YOU ARE RECEIVING A CEL 0401 "EGR Flow Insufficient", follow these next steps carefully. IF YOU ARE NOT RECEIVING A CODE, skip to step 19.
BEFORE REMOVING THE THROTTLE BODY, MAKE SURE YOU HAVE A REPLACEMENT THROTTLE BODY GASKET.
If you purchased the upper and lower gasket kit shown above, the gasket is included. If you just purchased the upper intake gaskets, the throttle body gasket is a seperate part number.
Using a 10 mm socket or wrench, remove the bolts holding the throttle body.
16) Look inside the throttle body at the bypass chamber. It is the 1/2 moon shaped port. Make sure it is free of debris and carbon. If not, clean it with spray throttle body cleaner.
17) Check the rest of the throttle body and clean as necessary with spray throttle body cleaner. DO NOT scratch the inside of the throttle body.
18) This view shows the replacement gasket installed. Re-attach the throttle body after throughly cleaning the upper intake with throttle body cleaner and paper towels.
19) Using the Super Secret, Ninja rubber gasket removal tool©®, (a device that looks eeriely similar to a common paper clip, unbent and with a 1/8" hook bent into one side). remove the gaskets and replace them with new gaskets from the kit ordered above.
If you are ONLY changing the spark plugs, stop here. Once the plugs are changed, the installation is the same procedure in reverse.
USE A TORQUE WRENCH WHEN RE-INSTALLING THE UPPER AND LOWER INTAKE MANIFOLD BOLTS.
All intake bolts are to be torqued to 89in/lbs.
If your torque wrench cannot do in/lbs, that is about 7.5 ft/lbs. (Or 89 divided by 12 because there is 12 inches in a foot).
If you are also replacing the lower intake manifold gaskets, proceed with these steps.
20) At this point, the lower intake manifolds and fuel rail is totally visible. To remove the lower intake manifolds, the fuel rail must first be removed. I STRONGLY SUGGEST STUFFING PAPER TOWELS INTO THE OPEN INTAKE MANIFOLD PORTS TO STOP ANYTHING FROM DROPPING INTO THE ENGINE. CAREFULLY disconnect the electrical plugs from each of the 6 fuel injectors. These plugs are brittle and can break easily. (Trust me on this one).
21) Using an 8mm socket, remove the 6 bolts holding the fuel rail. The left-most bolt is hidden below the electrical harness. You must move the harness out of the way in order to loosen that bolt.
22) Once the 6 bolts are removed, pull up on the fuel rail to disconnect it from the fuel injectors. Once the fuel rail is loose, set it aside. Remove the fuel injectors by pulling on them. Discard ALL the old O-rings on the fuel injectors and replace them. NOTE: I have heard you can remove the two lower intakes AND the fuel rail as one piece. I have not tried it this way, but it sounds possible. Here is a link to that thread. http://www.escape-central.com/1foru...14&pagenumber=2
Remove the bolts holding the lower intakes. Once all bolts are removed, a solid pull on the intakes will remove them.
23) This photo shows ALL of the replacement gaskets in place and the pile of "dead" gaskets to the left of the shiny new parts.
24) Before re-assembly, replace both the o-rings on each fuel injectors. Look at the spray end of the fuel injectors. They may need to be sprayed clean with the Throttle Body Cleaner.
25) Re-install the lower intake manifolds using the bolts you removed earlier. DO YOURSELF A FAVOR, coat each bolt with anti-sieze compound to make them easy to remove the next time you need to do replace gaskets. SEE PHOTO 26. The lower intake bolts are also torqued to 85 oz/in (7.5 ft/lbs).
26) Coating of anti-sieze compound applied to the lower intake bolts.
27) Re-install the fuel injectors. They are keyed and need to be pushed down into the lower intakes until they seat properly. It may take a little force to get the injectors back in with the new o-rings installed. Once all the injectors are properly inserted, re-install the fuel rail. Be careful to connect the fuel rail properly to each fuel injector. Replace the fuel rail bolts you removed earlier.
28) Once the lower intakes are back in place and the fuel rail is re-installed, the upper intake manifold is re-installed by going back to step 13 and following the procedure in reverse.
Last edited by lvon5401 on 07-09-2008 at 03:23 AM
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