QuestionI think I've done all the steps, including loosening even bolts in the front of the intake plenum, but it won't budge.
I'm not sure which are the egr, MAP and air intake sensors, but there doesn't appear to be anything keeping the plenum from moving.
AnswerHi Reif,
How is the car running, did you get the engine going again? If you would like to tell me there is a "Thank/rate the expert" button below which if you click will take you to page where you can "comment".
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Roland
Here are the steps from the manual:
INTAKE MANIFOLD/PLENUM - 2.5L ENGINE
REMOVAL
Disconnect negative cable from auxiliary jumper terminal Auxiliary Jumper Terminal
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.
Release fuel system pressure. Refer to Fuel System Pressure Release procedure in this section
WARNING: WRAP SHOP TOWELS AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.
Disconnect fuel supply tube from rail. Refer to Quick-Connect Fittings in the Fuel Delivery section of this group.
Unplug connectors from MAP and intake air temperature sensors Intake Manifold Sensors and Left Manifold Support Bolt
Remove plenum support bracket bolt located rearward of MAP sensor Intake Manifold Sensors and Left Manifold Support Bolt
Remove bolt holding air inlet resonator to intake manifold Air Inlet Resonator
Loosen throttle body air inlet hose clamp.
Release snaps holding air cleaner housing cover to housing.
Remove air cleaner cover and inlet hoses from engine.
Unplug TPS and idle air control motor connectors Throttle Position Sensor and Idle Air Control Motor
Squeeze retainer tab on throttle cable and slide cable out of bracket Throttle Cable Attachment
Slide Speed control cable out of bracket, if equipped Throttle Cable Attachment
Remove EGR tube from intake manifold EGR Tube and Right Manifold Support Bolt
Remove plenum support bracket bolt located rearward of EGR tube EGR Tube and Right Manifold Support Bolt
Remove 7 bolts holding upper intake plenum and remove plenum Intake and Exhaust Manifolds - 2.5L Engine
Disconnect electrical connectors from fuel injectors.
Remove 4 bolts holding fuel rail Fuel Rail Attachment
Lift fuel rail off engine. There are spacers under each fuel rail bolt Fuel Rail Spacers
Remove lower intake manifold attaching bolts. Remove intake manifold.
INSTALLATION
Install intake manifold with new gaskets. Tighten in sequence shown in Intake Manifold Tightening Sequence to 21 N·m (185 in. lbs.)
Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 N·m (8 ft. lbs.)
Attach electrical connectors to fuel injectors.
Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery Section of this Group.
Install new gasket and position upper intake plenum. Tighten plenum bolts to 18 N·m (13 ft. lbs.) torque.
Install bolts at plenum support brackets. Tighten bolts to 18 N·m (13 ft. lbs.)
Install EGR tube to plenum. Tighten EGR tube to intake manifold plenum screws to 11 N·m (95 in. lbs) torque.
Install throttle cables.
Attach electrical connectors to sensors.
Tighten air inlet tube clamps to 3 N·m ±1 (25 in. lbs. ±5)
Connect negative terminal to auxiliary jumper terminal.
It may just be a case of some adhesive or dried oil/gasket material that is holding the manifold in place so try gently prying between the manifold and the head, cautiously.
Roland
