Intake Manifold: Service and Repair

Intake Manifold Replacement

Special Tools

BO-38185 - Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.


The High Voltage Disabling procedure will perform the following tasks:


* Identify how to disable high voltage.

* Identify how to test for the presence of high voltage.

* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.


Failure to follow the procedures exactly as written may result in serious injury or death.


1. Disable the high voltage system. Refer to High Voltage Disabling High Voltage Disabling.
2. Drain the coolant fluid. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
3. Remove the Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
4. Remove the fuel injection fuel rail assembly only. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair




5. Remove the evaporative emission canister purge solenoid valve hose (1). Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.




6. Disconnect the heater outlet hose vapor vent hose (1).
7. Reposition the heater outlet vapor vent hose clamps using BO-38185 - Hose Clamp Pliers.
8. Reposition the outlet hose to a side.




9. Disconnect and reposition the secondary air pump hose (1).




10. Remove the intake manifold bolts (1).




11. Remove the intake manifold from the vehicle (1).
12. Disconnect electrical connectors as necessary.
13. To disassemble the intake manifold. Refer to Intake Manifold Disassemble 39. Intake Manifold Disassemble
14. For cleaning and inspection of the intake manifold. Refer to Intake Manifold Cleaning and Inspection 40. Intake Manifold Cleaning and Inspection.
15. Transfer components as necessary.

Installation Procedure




1. Ensure the surface of the intake manifold is clean before installing the new gasket.
2. Install the manifold gasket (1).




3. Install the intake manifold in the vehicle (1).





Caution: Refer to Fastener Caution Fastener Caution.

4. Install the intake manifold bolts (1).

Tighten the intake manifold bolts 20 Nm (15 lb ft).




5. Connect and reposition the secondary air pump hose (1).




6. Connect the heater outlet hose vapor vent hose (1).




7. Install the evaporative emission canister purge solenoid valve hose (1). Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.
8. Install the fuel injection fuel rail assembly only. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair.
9. Install the Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
10. Fill the coolant fluid. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
11. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.