Intake Manifold: Service and Repair

Intake manifold, removing and installing

Removing

Note: All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

- Drain coolant.

WARNING! Observe safety precautions when disconnecting the battery.

See Caution before beginning repairs on the electrical system

- Switch ignition off and disconnect battery Ground (GND) strap.




- Remove rear engine cover (arrows).




- Remove front engine cover (arrows).




- Remove cover -1- in engine compartment (right side).




- Remove bolts (arrows).
- Detach Evaporative Emissions (EVAP) Canister Purge Regulator Valve -N80 -1- at air guide.
- Remove air guide -2-.




- Remove air filter housing (arrows).
- Disconnect electrical harness connector -1- at Mass Air Flow (MAF) sensor.
- Remove air guide hose -2- together with Mass Air Flow (MAF) sensor.




- Disconnect vacuum hoses -2- and -3- at intake manifold change-over valve -N 156-.
- Disconnect vacuum hose -6- from check valve.




- Disconnect electrical harness connector-5-.
- Set aside hose of crankshaft housing ventilation (arrow).
- Remove bolts -1-, -4- and -7- for holding plate for solenoid valves.
- Remove holding plate for solenoid valves.
- Disconnect electrical harness connector-1-.
- Pull off vacuum hose -2- at T-connector.
- Remove all harness connectors to injectors.




- Disconnect vacuum line at fuel pressure regulator and remove mounting bolts of fuel pressure regulator (arrows).
- Remove fuel distributor together with fuel injectors from intake manifold simultaneously upward and place it on a clean rag in engine compartment.

Note: Carefully protect removed fuel injectors from contamination.




- Disconnect electrical harness connector -1- at throttle valve control module -J338-.
- Disconnect vacuum hoses -2- and -3-.




- Disconnect hose -1- from air duct.
- Remove bolt -4- and disconnect air duct -2- at throttle valve control module.
- If installed, disconnect vacuum hose -3- from air guide at bottom.




- Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.




- Remove bolts -1- and -3-.
- Pull out guide tube for oil dipstick 2 from the oil pan (upper part) toward top and swing it forward for removal.

Note: Hose 4 remains connected.




- Remove bolts at right side of engine (arrows) at line for secondary air injection.




- Remove bolts 1 and 2 at lines of secondary air injection.
- Unthread bolts -3- and -5- and remove resonator -4-.




- Disconnect vacuum hose -1- at EVAP valve.
- Remove coolant hoses -2- and -3-.




- Unbolt intake pipe (arrows) and remove.

Note: Plug intake channels in the cylinder heads with clean rags.

Installing

Installation is reverse of removal, noting the following:

Note: Secure all hose connections using hose clamps appropriate for the model type: Refer to Parts Supplier
Always replace seals and gaskets.





- Bolt in intake manifold in diagonal sequence in stages (arrows).
- Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).
See Caution for connecting Telematics battery

- Observe safety precautions after connecting the battery.
- Top up coolant.

Tightening torques