Intake Manifold: Service and Repair

Intake Manifold Removal and Installation

Intake Manifold:

Removal
1. Close the manual shut-off valve.





2. To reduce pressure in the fuel lines, start the engine, and run it until it stalls.
3. Remove the air cleaner assembly.
4. Remove the cowl cover and under-cowl panel.
5. Remove the intake air duct.





6. Remove the fuel feed hose.





7. Disconnect the vacuum hose (A), brake booster vacuum hose (B), positive crankcase ventilation (PCV) hose (C), and power steering (P/S) hose clamp (D).





8. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
^ Throttle actuator connector
^ Manifold absolute pressure (MAP) sensor connector
^ Intake manifold tuning (IMT) valve actuator connector

9. Disconnect the water bypass hoses, then plug the water bypass hoses.





10. Remove the throttle body.





11. Remove the heater hose clamp bracket.





12. Raise the vehicle on the lift to full height.
13. Remove the intake manifold bracket.





14. Lower the vehicle on the lift.
15. Remove the all intake manifold mounting bolts and nuts, then remove the intake manifold from the cylinder head.





16. Remove the harness clamps, then remove the intake manifold from the vehicle.





Installation
1. Install the harness clamps to the intake manifold.





2. Install the intake manifold (A) with new gaskets (B), and tighten the bolts and nuts in a crisscross pattern in three steps, beginning with the inner bolt.





3. Raise the vehicle on the lift to full height.
4. Install the intake manifold bracket (A).





5. Lower the vehicle on the lift.
6. Install the heater hose clamp bracket.





7. Install the throttle body (A) with a new gasket (B).





8. Install the water bypass hoses.





9. Connect the engine wire harness connectors, and install the wire harness clamps to the intake manifold.
^ Throttle actuator connector
^ Manifold absolute pressure (MAP) sensor connector
^ Intake manifold tuning (IMT) valve actuator connector

10. Install the vacuum hose (A), brake booster vacuum hose (B), positive crankcase ventilation (PCV) hose (C), and power steering (P/S) hose clamp (D).





11. Install the fuel feed hose (A). Use new O-ring (B).





12. Install the intake air duct.





13. Install the cowl panel and under-cowl cover.
14. Install the air cleaner assembly.
15. Clean up any spilled engine coolant.
16. After installation, check that all tubes, hoses and connectors are installed correctly.
17. Do the leak Inspection.
18. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open.