Intake Manifold: Service and Repair

Special Tools:

Removal

1. CAUTION: Disconnect the battery positive and ground cable.

Remove the battery.
2. Disconnect and remove the battery.
3. Raise and support the vehicle.





4. Remove the intake manifold bracket.
- Loosen the nuts and remove the bolts.

5. Lower the vehicle.





6. Remove the air cleaner housing.
1. Disconnect electrical connector of the Mass Air Flow (MAF) sensor.
2. Remove the intake hose.
- Remove the air cleaner housing from the rubber bushing.





7. Remove the accelerator cable.
1. Unhook the cable.
2. Pull off the plastic clip and position the accelerator cable aside.





8. Remove the speed control cable.
1. Unhook the cable.
2. Pull off the plastic clip and position the speed control cable aside.





9. Disconnect the positive crankcase ventilation hoses.





10. Remove the vacuum hoses.
1. EVAP solenoid valve vacuum hose
2. Brake booster vacuum hose
3. Delta Pressure Feedback Electronic System Sensor (DPFE)
4. Exhaust Gas Recirculation (EGR) Valve





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





12. Remove the vacuum hose.





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

Remove the coolant hoses from the intake manifold.





14. Disconnect the Throttle Position (TPS) Sensor and the Idle Air Control (IAC) valve.





15. Remove the oil level indicator tube.





16. Remove the intake manifold (shown with engine removed).
- Discard the gasket.

Installation





1. Install a new gasket and the intake manifold (shown with engine removed).
- Tighten the nuts and bolts to 10 Nm and 90 degrees.

2. Raise and support the vehicle.





3. Install the intake manifold bracket.
- Install the bolts and tighten the nuts.

4. Lower the vehicle.





5. Attach the DPFE hoses.





6. Install the oil level indicator tube.





7. Connect the TPS sensor and the IAC valve.





8. Attach the coolant hose to the intake manifold.
- Remove the clamps installed during removal procedure.





9. Attach the vacuum hose.





10. Connect the EGR valve.
- Install a new gasket.





11. Attach the vacuum hoses.
1. EVAP solenoid valve vacuum hose
2. Brake booster vacuum hose
3. DPFE
4. EGR valve





12. Connect the positive crankcase ventilation hose.
- Make sure the twist-lock positive crankcase ventilation valve is secure.





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





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





15. Install the air cleaner housing.
1. Connect the MAF sensor electrical connector.
2. Attach the intake hose.
- Install the air cleaner housing into the rubber bushing.

16. Install and connect the battery.