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. Failure to follow these instructions may result in 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. Failure to follow these instructions may result in personal injury.

1. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction.
2. Drain the cooling system. For additional information, refer to Cooling System.
3. Disconnect the battery ground cable. For additional information, refer to Battery.

4. 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).
5. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
6. Remove the cowl panel grille.
7. Disconnect the fuel supply tube spring lock coupling from the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.
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 evaporative emissions (EVAP) hose from the intake manifold.
13. Disconnect the fuel rail temperature sensor electrical connector.





14. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and the vacuum harness from the EGR system module.
15. Disconnect the EGR system module-to-exhaust manifold tube from the EGR system module.
16. Remove the crankcase ventilation tube.
17. Disconnect the vacuum supply tube.
18. Detach the vacuum harness retainers from the LH engine appearance cover bracket.
19. Detach the engine wiring harness from the engine appearance cover brackets.
20. Remove the 4 nuts and the 2 engine appearance cover brackets.





21. Disconnect the 8 fuel injectors and the radio interference ignition capacitor electrical connectors.





22. Remove the 2 nuts and the engine wiring harness retainer.
23. Remove the nut and the radio interference ignition capacitor.
24. Disconnect the 2 throttle body coolant tubes.

25. 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.
26. 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 in the sequence shown.
^ Tighten to 20 Nm (15 ft. lbs.).
3. Connect the 2 throttle body coolant tubes.
4. Install the radio interference ignition capacitors and nuts.
^ Tighten to 10 Nm (89 inch lbs.).





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





6. Connect the 8 fuel injectors and the radio interference ignition capacitor electrical connectors.
7. Install the 2 engine appearance cover brackets and the 4 nuts.
^ Tighten to 6 Nm (53 inch lbs.).
8. Attach the engine wiring harness to the engine appearance cover brackets.
9. Attach the vacuum harness retainers to the LH engine appearance cover bracket.





10. Connect the vacuum supply tube.
11. Install the crankcase ventilation tube.
12. Connect the EGR system module-to-exhaust manifold tube to the EGR system module.
^ Tighten to 40 Nm (30 ft. lbs.).
13. Connect the EGR system module electrical connector and the vacuum harness to the EGR system module.
14. Connect the fuel rail temperature sensor electrical connector.
15. Connect the EVAP hose to the intake manifold.
16. Connect the throttle body electrical connector.
17. Connect the fuel pressure sensor electrical connector and vacuum hose.
18. Connect the TP sensor electrical connector.
19. Install the 6 bolts and the cross-vehicle brace.
^ Tighten to 20 Nm (15 ft. lbs.).
20. Connect the fuel supply tube spring lock coupling to the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.
21. Install the cowl panel grille.
22. Install the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.

23. 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.
24. Connect the battery ground cable. For additional information, refer to Battery.
25. Fill and bleed the cooling system. For additional information, refer to Cooling System.