Intake Manifold: Service and Repair

Intake Manifold

Removal
1. Release the fuel pressure.
2. Unfasten the cable ties if necessary and install new ones when reinstalling.
3. Remove the generator.





4. Remove the air cleaner housing.
1 Pull off the mass air flow (MAF) sensor connector.
2 Detach the crankcase ventilation hose.
3 Detach the intake hose.
^ Pull out the air cleaner housing from the rubber bushings.





5. Detach the accelerator cable and the speed control cable (if equipped) from the throttle body.
6. Remove the fuel pressure sensor.





7. Detach the EGR valve and EGR pipe bracket.





8. Pull off the vacuum hoses.





9. Disconnect the fuel injector wiring.





10. Disconnect the camshaft position (CMP) sensor.





11. Detach the fuel line.





12. Remove the engine lifting eye.





13. Detach the intake manifold (graphic shows engine removed).
1 Remove the intake manifold studs on the front end of the engine.
2 Remove the five bolts and two nuts.

Installation





1. Install the intake manifold (graphic shows engine removed).

1 NOTE: Stud tightening torque = 10 Nm. Screw in the intake manifold studs.





2 Tighten the five bolts and two nuts.
2. Install the engine lifting eye.
3. Install the generator.
4. Install the fuel pressure sensor.





5. Install the fuel line.





6. Connect the camshaft position (CMP) sensor.





7. Connect the fuel injector wiring.





8. Install the vacuum hoses.





9. Install the EGR valve with a new gasket and EGR pipe bracket.





10. Install the accelerator cable. and the speed control cable (if equipped) to the throttle body.





11. Install the air cleaner housing.
^ Insert the air filter housing into the rubber bushings.
1 Attach the mass air flow (MAF) sensor connector.
2 Attach the crankcase ventilation hose.
3 Attach the intake hose.
12. If necessary, install new cable ties when reinstalling.

13. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 6 km (10 miles) or more to relearn the strategy.

Connect the battery ground cable.