Intake Manifold: Service and Repair

Intake Manifold Removal and Installation

Exploded View





Removal

1. Open the hood, and secure it with hood support rod (A) in the wide-open position (B).





2. Remove the bulkhead cover Front Bulkhead Cover Replacement.

3. Disconnect the fan motor connectors (A) and the hood switch connector (B), then remove the harness clips (C).






4. Remove the radiator upper brackets (A), then remove the front bulkhead (B).






5. Remove the engine cover.






6. Disconnect the breather pipe (A), then remove the air intake duct (B).






7. Disconnect the EVAP canister hose (A) and the brake booster vacuum hose (B).





8. Disconnect the water bypass hoses (C), then plug the water bypass hoses.

9. Disconnect the MAP sensor connector (A) and the throttle body connector (B), then remove the wire harness clamps (C).






10. Remove the intake manifold bracket.






11. Remove the intake manifold (A), then disconnect the PCV hose (B) from the intake manifold.

NOTE: Refer to the Exploded View if needed during this procedure.






Installation

1. Connect the PCV hose (A) to the intake manifold, then install the intake manifold (B) with new gaskets (C), and tighten the bolts and nuts in a crisscross pattern in three steps, beginning with the inner bolt.

NOTE: Refer to the Exploded View if needed during this procedure.






2. Install the intake manifold bracket.






3. Connect the MAP sensor connector (A) and the throttle body connector (B), then install the wire harness clamps (C).






4. Connect the water bypass hoses (A).





5. Connect the EVAP canister hose (B) and the brake booster vacuum hose (C).

6. Install the air intake duct (A), then connect the breather pipe (B).

NOTE: When tightening the screw of the hose band (C), align the edge of the hose band (D) with the mark (E) painted on the hose band. If you tighten the screw over the mark, replace the hose band.






7. Install the engine cover.






8. Install the front bulkhead (A), then install the radiator upper brackets (B).





9. Apply body paint to the bulkhead mounting bolts.

10. Connect the fan motor connectors (A) and the hood switch connector (B), then install the harness clips (C).






11. Install the bulkhead cover Front Bulkhead Cover Replacement.

12. Clean up any spilled engine coolant.

13. After installation, check that all tubes, hoses, and connectors are installed correctly.

14. Refill the radiator with engine coolant, and bleed the air from the cooling system Service and Repair.