Intake Manifold: Service and Repair

Intake Manifold





Material




















Removal

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

1. Release the fuel system pressure.
2. Disconnect the battery ground cable.





3. CAUTION: The engine appearance cover is equipped with a noise suppressor. If the noise suppressor becomes separated from the engine appearance cover it must be positioned on the intake manifold prior to installing the engine appearance cover.

Remove the engine appearance cover and the noise suppressor (if detached).
4. Remove the air cleaner outlet pipe.
5. Remove the cowl panel grille.
6. Disconnect the fuel supply tube spring lock coupling from the fuel rail.
7. Remove the Exhaust Gas Recirculation (EGR) system module.
8. Remove the 6 bolts and the cross vehicle brace.
9. Disconnect the Throttle Position (TP) sensor electrical connector.
10. Disconnect the fuel pressure sensor electrical connector and vacuum hose.
11. Disconnect the throttle body electrical connector.
12. Disconnect the EVAP hose from the intake manifold.
13. Disconnect the fuel rail temperature sensor electrical connector.
14. Remove the crankcase ventilation tube.





15. Disconnect the vacuum supply tube.
16. Detach the vacuum harness retainers from the LH engine appearance cover bracket.
17. Detach the engine wiring harness from the engine appearance cover brackets.
18. Remove the 4 nuts and the 2 engine appearance cover brackets.
19. Disconnect the 8 fuel injector electrical connectors.
20. Disconnect the radio interference ignition capacitor electrical connector.





21. Remove the 2 nuts and the engine wiring harness retainer.
22. Remove the nut and the radio interference ignition capacitor.
23. Remove the 4 fuel rail bolts.
24. Remove the fuel rail and injectors as an assembly.
25. Remove the clips and the 8 fuel injectors from the fuel rail.
26. Remove and discard the 16 O-ring seals from the fuel injectors.
27. Disconnect and plug the 2 throttle body coolant tubes.





28. NOTE: The throttle body and adapter are shown removed for clarity. It is not necessary to remove the throttle body and adapter to remove the intake manifold.

Remove the 7 bolts and 3 studs in the sequence shown.
29. Remove the intake manifold and discard the gaskets.

Installation

1. 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 clean the surfaces.

Clean the gasket sealing surfaces.





2. Install new gaskets, the intake manifold, the 7 bolts and the 3 studs.
^ Tighten the 7 bolts and the 3 studs in the sequence shown to 20 Nm (15 ft. lbs.).

3. Unplug and connect the 2 throttle body coolant tubes.
4. CAUTION: Use O-ring seals that are made of special fuel resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.

Install 16 new O-ring seals onto the fuel injectors.
^ Lubricate the O-ring seals with clean engine oil.

5. Install the fuel injectors and clips onto the fuel rail.
6. Install the fuel rail and injectors as an assembly.
7. Install the 4 fuel rail bolts.
^ Tighten to 10 Nm (89 inch lbs.).

8. Install the radio interference ignition capacitors and nuts.
^ Tighten to 10 Nm (89 inch lbs.).





9. Install the engine wiring harness retainer and the 2 nuts.
^ Tighten to 10 Nm (89 inch lbs.).

10. Connect the radio interference ignition capacitor electrical connectors.
11. Connect the 8 fuel injector electrical connectors.
12. Install the 2 engine appearance cover brackets and the 4 nuts.
^ Tighten to 6 Nm (53 inch lbs.).

13. Attach the engine wiring harness to the engine appearance cover brackets.
14. Attach the vacuum harness retainers to the LH engine appearance cover bracket.





15. Connect the vacuum supply tube.
16. Install the crankcase ventilation tube.
17. Connect the fuel rail temperature sensor electrical connector.
18. Connect the EVAP hose to the intake manifold.
19. Connect the throttle body electrical connector.
20. Connect the fuel pressure sensor electrical connector and vacuum hose.
21. Connect the TP sensor electrical connector.
22. Install the 6 bolts and the cross vehicle brace.
^ Tighten to 20 Nm (15 ft. lbs.).

23. Install the EGR system module.
24. Install the air cleaner outlet pipe.
25. Connect the fuel supply tube spring lock coupling to the fuel rail.





26. CAUTION: The engine appearance cover is equipped with a noise suppressor. If the noise suppressor becomes separated from the engine appearance cover it must be positioned on the intake manifold prior to installing the engine appearance cover.

Install the noise suppressor (if detached) and the engine appearance cover.
27. Install the cowl panel grille.
28. Connect the battery ground cable.