Intake Manifold - VIN Range: G00442->G45703 (30.15.01)

Intake Manifold - VIN Range: G00442->G45703 (30.15.01)

Removal
1. Remove the cowl vent screen.
2. Remove the air cleaner outlet pipe. Refer to Fuel Delivery and Air Induction.
3. Remove the engine compartment support.





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. WARNING: TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE COOLING SYSTEM, USE EXTREME CARE WHEN REMOVING THE COOLANT PRESSURE CAP FROM A HOT COOLING SYSTEM. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE COOLANT PRESSURE CAP AND TURN IT SLOWLY UNTIL THE PRESSURE BEGINS TO RELEASE. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE SYSTEM. WHEN CERTAIN ALL THE PRESSURE HAS BEEN RELEASED (STILL WITH A CLOTH) TURN AND REMOVE THE COOLANT PRESSURE CAP FROM THE COOLANT EXPANSION TANK. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

Remove the coolant expansion tank cap.

8. NOTE: Cap the coolant hose.

Disconnect the throttle body coolant hose.





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





10. Remove the left-hand engine cover bracket.





11. NOTE: Right-hand shown left-hand similar.

Detach the engine wiring harness.





12. NOTE: Right-hand shown left-hand similar.

Disconnect the fuel injector electrical connectors.





13. Detach the fuel line. Refer to Fuel Delivery and Air Induction.
14. Detach the left-hand camshaft position sensor electrical connector.





15. Disconnect the coolant temperature sensor electrical connector.





16. Remove the right-hand engine cover bracket.





17. Remove the positive crankcase ventilation (PCV) valve.





18. Disconnect the fuel pressure regulator electrical connector.





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





20. NOTE: Cap the coolant hose.

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





21. Detach the right-hand engine wiring harness.





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





23. Disconnect the fuel temperature sensor electrical connector.





24. Disconnect the right-hand camshaft position (CMP) sensor.





25. Detach the brake booster vacuum pipe.





26. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.





27. Detach the engine wiring harness.





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





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





Installation

1. CAUTION: Make sure that all gasket mating faces are clean and dry.

Install the intake manifold.

^ Install new gaskets.
^ Tighten to 22 Nm.





2. Attach the exhaust gas recirculation (EGR) valve tube.
^ Install a new gasket.
^ Tighten to 22 Nm.





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 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 O-ring seals.
^ Attach the fuel line retaining clip.





18. NOTE: Right-hand shown left-hand similar.

Connect the fuel injector electrical connectors.





19. NOTE: Left-hand shown right-hand similar.

Attach the 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. NOTE: Left-hand shown, right-hand similar.

Install the on-plug coil covers.





26. Install the engine compartment support.
^ Tighten to 18 Nm.





27. Install the air cleaner outlet pipe. Refer to Fuel Delivery and Air Induction.
28. Install the cowl vent screen.
29. Check and top up the cooling system.