Intake Manifold: Service and Repair

Intake Manifold











Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction.
2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
3. Remove the fuel rail and injectors. For additional information, refer to Fuel Delivery and Air Induction.
4. Disconnect the evaporative emissions (EVAP) tube from the intake manifold and position the tube aside.
5. Disconnect the PCV tube from the intake manifold, LH valve cover and remove.
6. Disconnect the throttle position (TP) sensor and electronic throttle body (TB) electrical connectors.
7. Disconnect the charge motion control valve (CMCV) electrical connector.
8. Detach the wiring retainers from the intake manifold stud bolt and the CMCV bracket and then position the wiring harness aside.
9. Disconnect the vacuum hose from the T-fitting.

10. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Remove the 9 bolts, the stud bolt and the intake manifold.
^ Discard the gaskets.





Installation

1. NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at rear of the intake manifold. Use extreme care on installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.

Using new intake manifold gaskets, position the intake manifold.
2. Install the intake manifold bolts and stud bolt.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





3. Connect the vacuum hose to the T-fitting.
4. Position the wiring harness and attach the wiring retainers to the intake manifold stud bolt and the CMCV bracket.
5. Connect the CMCV electrical connector.
6. Connect the TP sensor and electronic TB electrical connectors.
7. Connect the PCV tube to the intake manifold.
8. Connect the EVAP tube to the intake manifold.
9. Install the fuel rail and injectors.
10. Install the air cleaner outlet pipe.