Intake Manifold: Service and Repair

Intake Manifold

Intake Manifold (View 1 of 2)









Intake Manifold (View 2 of 2)

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Removal

1. Remove the air cleaner outlet tube. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.

2. Disconnect the crankcase vent tube from the valve cover.
- Detach the 2 crankcase vent tube retainers.





3. Remove the fuel rail. For additional information, refer to Fuel Charging and Controls - 1.6L Fuel Rail.

4. Remove the generator. For additional information, refer to Charging System Service and Repair.

5. Remove the screw and the oil level indicator and tube.
- Inspect and replace the O-ring seal, if necessary.





6. Disconnect the Throttle Body (TB) electrical connector.
- Detach the wiring harness retainer from the TB.





7. Disconnect the PCV hose from the intake manifold.





8. Remove the bolt for the Evaporative Emission (EVAP) canister purge valve.





9. Disconnect the brake booster vacuum tube from the intake manifold.





10. Disconnect the EVAP canister purge valve tube from the intake manifold and position the EVAP canister purge valve aside.





11. Detach the Knock Sensor (KS) electrical connector from the bottom of the intake manifold.
- Detach the 2 wiring harness retainers from the bottom of the intake manifold.





12. Remove the 7 bolts for the intake manifold.





Installation

NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

1. Inspect and install new intake manifold gaskets, if necessary.





2. Install the intake manifold and the 7 bolts.
- Tighten to 18 Nm (159 lb-in).





3. Attach the KS electrical connector to bottom of the intake manifold.
- Attach the 2 wiring harness retainers to the bottom of the intake manifold.





4. Position and connect the EVAP canister purge valve tube to the intake manifold.





5. Connect the brake booster vacuum tube to the intake manifold.





6. Install the bolt for the EVAP canister purge valve.
- Tighten to 9 Nm (80 lb-in).





7. Connect the PCV hose to the intake manifold.





8. Connect the TB electrical connector.
- Attach the wiring harness retainer to the TB.





9. NOTE: Lubricate the O-ring seal with clean engine oil.

Install the oil level indicator and tube and the screw.

- Tighten to 4 Nm (35 lb-in).





10. Install the generator. For additional information, refer to Charging System Service and Repair.

11. Install the fuel rail. For additional information, refer to Fuel Charging and Controls - 1.6L Fuel Rail.

12. Connect the crankcase vent tube to the valve cover.
- Attach the 2 crankcase vent tube retainers.





13. Install the air cleaner outlet tube. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.