Intake Manifold: Service and Repair

Intake Manifold Removal and Installation

Intake Manifold:

Removal
1. Drain the engine coolant.
2. Remove the engine cover.
3. Remove the resonator.
4. Remove the air intake duct.
5. Remove the air cleaner.
6. Remove the front grill cover.





7. Raise the vehicle on the hoist to full height.
8. Remove the front wheels.
9. Remove the splash shield.
10. Remove the intake manifold stay bolts (A) and the A/C compressor harness clamp (B).





11. Lower the vehicle on the hoist.
12. Remove the water bypass hose (A) and the vacuum hose (B), then disconnect the throttle body connector (C).





13. Remove the water bypass hose (A).





14. Disconnect the EGR harness connector (A), the intake manifold sub-harness connector (B), and the clamp (C), then remove the ground cable (D).





15. Disconnect the fuel injector harness connectors (A), the rocker arm oil control solenoid connectors (B), and the EOP sensor connector (C), then remove the engine wire harness from the clamps (D).





16. Remove the positive crankcase ventilation (PCV) hose (A).





17. Remove the intake manifold assembly.





Installation
1. Install the intake manifold assembly (A) and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. Use a new gasket (B).





2. Install the PCV hose (A).





3. Connect the engine wire harness to the clamps (A), then connect the fuel injector harness connectors (B) and the rocker arm oil control solenoid valve connectors (C).





4. Connect the EGR harness connector (A), the intake manifold sub-harness connector (B), and the clamp (C), then remove the ground cables (D).





5. Install the water bypass hose (A).





6. Install the water bypass hose (A) and the vacuum hose (B), then connect the throttle body connector (C).





7. Raise the vehicle on the hoist to full height.
8. Install the intake manifold stay bolts (A), then install the A/C compressor harness clamp (B).





9. Install the splash shield.
10. Install the front wheels.
11. Lower the vehicle on the hoist.
12. Install the front grill cover.





13. Install the air cleaner.
14. Install the air intake duct.
15. Install the resonator.
16. Install the engine cover.
17. Clean up any spilled engine coolant.
18. After installation, check that all tubes, hoses, and connectors are installed correctly.
19. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.