Intake Manifold: Service and Repair

Intake Manifold Removal and Installation

Exploded View





NOTE: Refer to the Exploded View needed during this procedure.

Removal

1. Drain the engine coolant Service and Repair.

2. Remove the engine cover Engine Removal.

3. Remove the intake air resonator Service and Repair.

4. Remove the intake air duct Engine Removal.

5. Remove the air cleaner Service and Repair.

6. Remove the front grille cover.






7. Raise the vehicle on the lift.

8. Remove the front wheels.

9. Remove the front undercover and the splash shield Engine Removal.

10. Remove the intake manifold bracket bolts (A) and the A/C compressor harness clamp (B).






11. Lower the vehicle on the lift.

12. Disconnect the water bypass hose (A) and the vacuum hose (B), and the throttle body connector (C).






13. Disconnect the water bypass hose (A).






14. Disconnect the EGR valve connector (A) and the intake manifold sub-harness connector (B), then remove the clamp (C) and the ground cables (D).






15. Disconnect the fuel injector connectors (A), the rocker arm oil control valve connectors (B), and the rocker arm oil pressure sensor connector (C), then remove the engine wire harness from the brackets (D).






16. Disconnect the PCV hose (A).






17. Remove the intake manifold assembly.






Installation

1. Install the intake manifold assembly (A) and tighten the bolts/nuts in a crisscross pattern in three steps, beginning with the inner bolt. Use a new gasket (B).






2. Connect the PCV hose (A).






3. Install the engine wire harness to the brackets (A), then connect the fuel injector connectors (B), the rocker arm oil control valve connectors (C), and the rocker arm oil pressure sensor connector (D).






4. Connect the EGR valve connector (A) and the intake manifold sub-harness connector (B), then install the clamp (C) and the ground cables (D).






5. Connect the water bypass hose (A).






6. Connect the water bypass hose (A) and the vacuum hose (B), and the throttle body connector (C).





7. Raise the vehicle on the lift.

8. Install the intake manifold bracket bolts (A), then install the A/C compressor harness clamp (B).





9. Install the splash shield and the front undercover Engine Installation.

10. Install the front wheels.

11. Lower the vehicle on the lift.

12. Install the front grille cover.






13. Install the air cleaner Service and Repair.

14. Install the intake air duct Engine Installation.

15. Install the intake air resonator Service and Repair.

16. Install the engine cover Engine Installation.

17. Clean up any spilled engine coolant.

18. After installation, check that all tubes, hoses, and connectors are installed correctly.

19. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open Service and Repair.