Intake Manifold: Service and Repair

Intake Manifold Replacement

Special Tools

EN-34730-91 - Pressure Tester

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

Removal Procedure

1. Open hood.

2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

3. Remove engine sight shield.





4. Unclip the heater outlet hose from retainer clip (1).

5. Unclip the engine control module wiring harness from 2 retainer clips (2).

6. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement (Automatic Transmission) Charge Air Cooler Outlet Air Hose Replacement (Automatic Transmission)Charge Air Cooler Outlet Air Hose Replacement (Manual Transmission) Charge Air Cooler Outlet Air Hose Replacement (Manual Transmission).





7. Disconnect the throttle body wiring harness plug (1).





8. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (3).

Note:
Make note of the installed position of the manifold absolute pressure sensor wiring harness plugs to ensure they will be connected in their original position.

9. Disconnect the 2 manifold absolute pressure sensor wiring harness plugs (1) and (2).

10. Disconnect the 4 fuel injector wiring harness plugs (4).

11. Unclip the engine control module wiring harness from the camshaft cover.





12. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).

13. Unclip the engine control module wiring harness from 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1).

Warning

Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.





14. Remove fuel injector rail cap (1).





15. Relieve the fuel system pressure. Use EN-34730-91 - pressure tester(1).





16. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service.

17. Unclip fuel feed pipe from the retainer clip.

18. Disconnect the positive crankcase ventilation pipe from the intake manifold. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Service and Repair





19. Disconnect the fuel ventilation pipe (1) from the evaporative emission canister purge solenoid valve.

20. Unclip the fuel ventilation pipe from the retainer clip.





21. Disconnect the brake booster vacuum pipe (1) from intake manifold.





Note:
Intake manifold bolts remain in intake manifold. Note the installation of the fuel rail ground strap for proper installation.

22. Remove the 6 intake manifold bolts (1).





23. Remove the intake manifold (1).

24. Remove and DISCARD the intake manifold gasket.

25. Remove the assembly parts from the intake manifold as necessary. Refer to Intake Manifold Disassemble Intake Manifold Disassemble.

Installation Procedure

1. Install the assembly parts to the intake manifold as necessary. Refer to Intake Manifold Assemble Intake Manifold Assemble.

2. Clean the sealing surfaces.





3. Install the intake manifold (1) along with a NEW intake manifold gasket.





Caution:
Refer to Fastener Caution Fastener Caution.

Note:
Install the fuel rail ground strap to the appropriate intake manifold bolt.

4. Install the 6 intake manifold bolts (1) and tighten to 20 Nm(15 lb ft).





5. Connect the fuel ventilation pipe (1) to the evaporative emission canister purge solenoid valve.

6. Clip in the fuel ventilation pipe to retainer clip.

7. Connect the positive crankcase ventilation pipe to the intake manifold. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Service and Repair





8. Connect the fuel feed pipe (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service.

9. Clip in the fuel feed pipe to retainer clip.





10. Connect the brake booster vacuum pipe (1) to the intake manifold.





11. Install fuel injector rail cap (1).





12. Connect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).

13. Clip in the engine control module wiring harness to 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1).





14. Clip in the engine control module wiring harness to the camshaft cover.

15. Connect the 4 fuel injector wiring harness plugs (4).

16. Connect the 2 manifold absolute pressure sensor wiring harness plugs (1) and (2).

17. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (3).





18. Connect the throttle body wiring harness plug (1).

19. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement (Automatic Transmission) Charge Air Cooler Outlet Air Hose Replacement (Automatic Transmission)Charge Air Cooler Outlet Air Hose Replacement (Manual Transmission) Charge Air Cooler Outlet Air Hose Replacement (Manual Transmission).





20. Clip in the heater outlet hose to retainer clip (1).

21. Clip in the engine control module wiring harness to 2 retainer clips (2).

22. Install the engine sight shield.

23. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

24. Close the hood.