Intake Manifold: Service and Repair

Intake Manifold Removal and Installation

Intake Manifold:

Removal
1. Relieve the fuel pressure.
2. Remove the charge air cooler.
3. Remove the fuel injector cover.





4. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
^ Four fuel injector connectors
^ Throttle actuator connector
^ Manifold absolute pressure (MAP) sensor connector
^ Intake manifold temperature (IAT) sensor connector
^ Turbocharger bypass control solenoid valve connector

5. Remove the quick-connect fitting cover (A), then disconnect the fuel feed hose.





6. Remove the ground cable (A), vacuum hoses (B), brake booster vacuum hose (C), and turbocharger bypass control solenoid valve bracket mounting bolt (D).





7. Remove the evaporative emission (EVAP) canister hose (A) and water bypass line bracket mounting bolt (B).





8. Remove the water bypass hoses (C), then plug the water bypass hoses.
9. Remove the positive crankcase ventilation (PCV) hose (A) and harness holder (B).





10. Remove the harness clamp (A) and connector (B), then remove the intake manifold bracket (C).





11. Remove the intake manifold.





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





2. Install the intake manifold bracket (A), then install the harness clamp (B) and connector (C).





3. Install the PCV hose (A) and harness holder (B).





4. Install the water bypass hoses (A), EVAP canister hose (B), and water bypass line bracket mounting bolt (C).





5. Install the ground cable (A), vacuum hoses (B), brake booster vacuum hose (C), and turbocharger bypass control solenoid valve bracket mounting bolt (D).





6. Connect the fuel feed hose, then install the quick-connect fitting cover (A).





7. Connect the engine wire harness connectors, and install the wire harness clamps to the intake manifold.
^ Four fuel injector connectors
^ Throttle actuator connector
^ MAP sensor connector
^ IAT sensor connector
^ Turbocharger bypass control solenoid valve connector

8. Install the fuel injector cover.





9. Install the charge air cooler.
10. Clean up any spilled engine coolant.
11. After installation, check that all tubes, hoses, and connectors are installed correctly.
12. Inspect for fuel leaks: Turn the ignition switch ON (II) (do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
13. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open.