Intake Manifold: Service and Repair

Intake Manifold
Removal
1. Remove the cowl vent screen.
2. Remove the air cleaner outlet pipe.





3. Remove the engine compartment brace.





4. NOTE: Left-hand shown, right-hand similar.

Remove the on-plug coil covers.





5. Disconnect the Throttle Potentiometer (TP) electrical connector.





6. Disconnect the throttle motor electrical connector.





7. NOTE: Cap the coolant system hose to minimize coolant loss

Disconnect the throttle body coolant hose.





8. Disconnect the knock sensors (KS) electrical connectors.




9. Remove the left-hand engine cover bracket.





10. Detach the left-hand engine wiring harness.





11. Disconnect the left-hand fuel injector electrical connectors.
12. Detach the fuel line.





13. Detach the left-hand camshaft position sensor electrical connector.





14. Disconnect the coolant temperature sensor electrical connector.




15. Remove the right-hand engine cover bracket.





16. Remove the Positive Crankcase Ventilation (PCV) valve.





17. Disconnect the fuel pressure regulator electrical connector.





18. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.





19. NOTE: Cap the coolant hose.

Disconnect the Exhaust Gas Recirculation (EGR) valve coolant hose.





20. Detach the right-hand engine wiring harness.





21. Disconnect the right-hand fuel injector electrical connectors.





22. Disconnect the fuel temperature sensor electrical connector.





23. Disconnect the right-hand Camshaft Position (CMP) sensor.





24. Detach the brake booster vacuum pipe.





25. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.





26. Detach the engine wiring harness.





27. Detach the exhaust gas recirculation (EGR) valve tube.
^ Remove and discard the gasket.





28. Remove the intake manifold.
^ Remove and discard the gaskets.

Installation





1. Install the intake manifold.
^ Install new gaskets.
^ Tighten to 22 Nm.





2. Attach the exhaust gas recirculation (EGR) valve tube.
^ Install a new gasket.





3. Attach the engine wiring harness.
^ Tighten to 10 Nm.





4. Connect the manifold absolute pressure (MAP) sensor electrical connector.





5. Connect the right-hand camshaft position (CMP) sensor.





6. Connect the fuel temperature sensor electrical connector.





7. Attach the brake booster vacuum pipe.





8. Connect the right-hand fuel injector electrical connectors.





9. Attach the right-hand engine wiring harness.





10. NOTE:
Remove the cap from the coolant hose.

Connect the exhaust gas recirculation (EGR) valve coolant hose.





11. Connect the exhaust gas recirculation (EGR) valve electrical connector.





12. Connect the fuel pressure regulator electrical connector.





13. Install the positive crankcase ventilation (PCV) pipe.





14. Install the right-hand engine cover bracket.
^ Tighten to 6 Nm.





15. Connect the coolant temperature sensor electrical connector.





16. Attach the left-hand camshaft position sensor electrical connector.





17. Connect the fuel line.
^ Install new 0-ring seals.
^ Attach the fuel line retaining clip.





18. Correct the left-hand fuel injector electrical correctors.





19. Attach the left-hand engine wiring harness.





20. Install the left-hand engine cover bracket.
^ Tighten to 6 Nm.





21. Connect the knock sensor (KS) electrical connectors.





22. NOTE:
Remove the cap from the coolant hose.

Connect the throttle body coolant hose.





23. Connect the throttle motor electrical connector.





24. Connect the throttle potentiometer (TP) electrical connector.





25. Install the engine compartment brace.
^ Tighten to 18 Nm.
26. Install the air cleaner outlet pipe.
27. Install the cowl vent screen.
28. Check and top up the cooling system.