Intake Manifold: Service and Repair

Intake Manifold





Special Tool(s)

Removal
1. Release the fuel pressure.
2. Disconnect the battery ground cable.
3. Raise and support the vehicle.





4. Detach the intake manifold bracket.
^ Loosen the nuts and remove the bolts.
5. Lower the vehicle.





6. Remove the air cleaner housing.
1. Disconnect the mass air flow (MAF) sensor electrical connector.
2. Disconnect the air cleaner outlet hose.
^ Remove the air cleaner housing from the rubber bushing.





7. Disconnect the accelerator cable.
1. Unhook the cable.
2. Remove the plastic clip and position the accelerator cable to one side.





8. Disconnect the speed control cable.
1. Unhook the cable.
2. Remove the plastic clip and position the speed control cable to one side.





9. Disconnect the positive crankcase ventilation hoses.





10. Disconnect the vacuum hoses.
1. EVAP solenoid valve.
2. Brake booster.
3. Delta pressure feedback electronic (DPFE) system sensor.
4. Exhaust gas recirculation (EGR) valve.





11. Disconnect the EGR valve.
^ Discard the gasket.





12. NOTE: Clamp the hoses to prevent coolant loss.

Disconnect the coolant hoses from the intake manifold.





13. Remove the vacuum hose assembly.





14. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve.





15. NOTE: Do not remove the oil level indicator tube.

Remove the bolt and bracket from the oil level indicator tube.





16. Remove the intake manifold upper support bracket.





17. Disconnect the fuel injector electrical connectors.





18. Disconnect the electrical connectors.
1. Intake manifold runner control (IMRC).
2. Camshaft position (CMP) sensor.
3. Ignition coil.
19. Disconnect the fuel lines from the fuel rail.





20. Remove the intake manifold retainers and position the manifold to the rear of the engine compartment (shown with engine removed).





21. Remove the IMRC manifolds (shown with engine removed).
^ Remove the two studs first.
^ Discard the gaskets.





22. Remove the intake manifold from the engine compartment.

Installation





1. Position the intake manifold to the rear of the engine compartment (shown with engine removed).





2. NOTE: Use new gaskets.

Install the IMRC manifolds and the two studs (shown with engine removed).
^ Tighten the studs in two stages.
^ Stage 1: 10 Nm.
^ Stage 2: 90 degrees.





3. NOTE: Use new gaskets.

Install the intake manifold and retainers (shown with engine removed).
^ Tighten the nuts and bolts in two stages
^ Stage 1: 10 Nm.
^ Stage 2: 90 degrees.
4. Connect the fuel lines to the fuel rail.





5. Connect the electrical connectors.
1. Ignition coil.
2. CMP sensor.
3. IMRC.





6. Connect the fuel injector electrical connectors.





7. Install the intake manifold upper support bracket.
8. Raise and support the vehicle.





9. Attach the intake manifold bracket.
^ Install the bolts and tighten the nuts.
10. Lower the vehicle.





11. Install the bracket and bolt to the oil level indicator tube.





12. Connect the TP sensor and the IAC valve.





13. Connect the coolant hoses to the intake manifold.
^ Remove the clamps.





14. Install the vacuum hose assembly.





15. Connect the EGR valve.
^ Install a new gasket.





16. Connect the vacuum hoses.
1. EVAP solenoid valve.
2. Brake booster.
3. DPFE system sensor.
4. EGR valve.





17. Connect the positive crankcase ventilation hoses.
^ Make sure the twist-lock positive crankcase ventilation valve is secure.





18. Connect the speed control cable.
1. Connect the cable.
2. Position the speed control cable and install the plastic clip.





19. Connect the accelerator cable.
1. Connect the cable.
2. Position the accelerator cable and install the plastic clip.





20. Install the air cleaner housing.
1. Connect the MAF sensor electrical connector.
2. Connect the air cleaner outlet hose.
^ Install the air cleaner housing into the rubber bushing.
21. Connect the battery ground cable.