Intake Manifold Replacement
Intake Manifold Replacement
Removal Procedure
Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
1. Loosen the clamps at the throttle body and air cleaner.
2. Remove the air cleaner outlet duct.
3. Unsnap the intake manifold sight shield from the stud.
4. Remove the sight shield from the bracket.
5. Remove the sight shield bracket nuts (1) and bracket, if necessary.
6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
7. Disconnect the fuel feed and return pipes.
8. Disconnect the engine harness clips from the studs on the front of dash.
9. Disconnect the engine harness clip from the wheelhouse splash shield.
10. Disconnect the following electrical connectors:
^ Pressure cycling switch (1)
^ Surge tank switch (2)
^ Mass airflow (MAF) sensor (3)
11. Reposition the engine harness branch to top of engine.
12. Remove the connector position assurance (CPA) retainer at the ignition coil harness.
13. Disconnect the following electrical connectors:
^ Manifold absolute pressure (MAP) sensor (1)
^ Ignition coil harness (2)
^ Engine coolant temperature (ECT) sensor (3)
14. Remove the engine harness bolt and studs
15. Remove the CPA retainer at the ignition coil harness.
16. Disconnect the following electrical connectors:
^ Generator (2)
^ Injector harness (3)
^ Ignition coil harness (4)
^ Electronic throttle control (ETC) (5)
^ Purge valve solenoid (1)
17. Reposition the engine harness to the drivers side of the engine compartment.
18. Remove the bypass valve vacuum hose (1) from the intake manifold.
19. Disconnect the evaporative emission (EVAP) tube from the purge solenoid.
20. Unclip the EVAP tube from the fuel rail.
21. Disconnect the EVAP tube from the vent pipe at the rear of the engine.
22. Remove the EVAP tube.
23. If replacing the intake manifold, remove the fuel rail studs.
24. Remove the fuel rail.
25. Important: Do not attempt to loosen the manifold by prying under the gasket surface with any tool.
Remove the intake manifold bolts.
26. Remove the intake manifold.
27. Important: The intake manifold gaskets are not reusable.
Remove and discard the intake manifold side gaskets.
28. Remove and discard the intake manifold end seals.
29. Important: The splash shield is secured using a snap-in fit. Do not distort the splash shield. The splash shield is reusable.
Remove the splash shield.
30. If replacing the intake manifold, refer to Intake Manifold Disassemble.
31. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection.
Installation Procedure
1. If replacing the intake manifold, refer to Intake Manifold Assemble.
2. Install the splash shield.
3. Ensure the splash shield (2) snap fits between the cylinder heads (1).
4. Apply a 5 mm (0.2 inch) bead of sealer to the intake manifold. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
5. Install the NEW intake manifold end seals.
6. Apply a 5 mm (0.2 inch) bead of sealer (1) onto the end seals. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
7. Install the NEW intake manifold side gaskets.
8. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
9. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.
10. Install the intake manifold.
11. Install NEW intake manifold bolts.
12. Notice: Refer to Fastener Notice in Service Precautions.
Tighten the intake manifold bolts in the sequence shown, using 4 passes.
1. Tighten the bolts a first pass to 5 Nm (44 inch lbs.).
2. Tighten the bolts a second pass to 8 Nm (71 inch lbs.).
3. Tighten the bolts a third pass to 12 Nm (106 inch lbs.).
4. Tighten the bolts a final pass to 15 Nm (11 ft. lbs.).
13. Important: Lubricate the fuel injector O-ring seals with clean engine oil and install onto the spray tip of each injector.
If replacing the intake manifold, install the fuel rail.
14. Install the fuel rail studs.
Tighten the studs to 12 Nm (106 inch lbs.).
15. Install the EVAP tube.
16. Connect the EVAP tube to the vent pipe at the rear of the engine.
17. Clip the EVAP tube to the fuel rail.
18. Connect the EVAP tube to the purge solenoid.
19. Install the bypass valve vacuum hose (1) to the intake manifold.
20. Position the engine harness over the engine compartment.
21. Connect the following electrical connectors:
^ Generator (2)
^ Injector harness (3)
^ Ignition coil harness (4)
^ ETC (5)
^ Purge valve solenoid (1)
22. Install the CPA retainer at the ignition coil harness.
23. Install the engine harness bolt and studs.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).
^ Tighten the studs to 10 Nm (89 inch lbs.).
24. Connect the following electrical connectors:
^ MAP sensor (1)
^ Ignition coil harness (2)
^ ECT sensor (3)
25. Install the CPA retainer at the ignition coil harness.
26. Position engine harness branch over the top of engine.
27. Connect the following electrical connectors:
^ Pressure cycling switch (1)
^ Surge tank switch (2)
^ MAF sensor (3)
28. Connect the engine harness clip to the wheelhouse splash shield.
29. Connect the engine harness clips to the studs on the front of dash.
30. Connect the fuel feed and return pipes.
31. Install the sight shield bracket and nuts (1).
Tighten the nuts to 5 Nm (44 inch lbs.).
32. Install the sight shield to the bracket.
33. Snap the intake manifold sight shield to the stud.
34. Install the air cleaner outlet duct.
35. Tighten the clamps at the throttle body and air cleaner.
Tighten the clamps to 4 Nm (35 inch lbs.).