Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure





1. Release fuel pressure in fuel feed.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Drain the coolant.
4. Remove the Front Suspension support brace.
5. Remove the 4 screws and the fuel injector sight shield.
6. Remove the air cleaner upper case, the intake air hose, the intake air pipe (2) and the surge tank pipe (1) as one component.





7. Disconnect the accelerator cable (2) from the throttle body.
8. If the vehicle has an automatic transmission disconnect the automatic transmission throttle cable (1) from the throttle body.
9. Disconnect the water hoses (3) from the throttle body.





10. Disconnect the injector wire coupler (1).
11. Disconnect the brake booster hose (2) from the intake manifold.





12. Disconnect the following electrical connectors:
- The throttle position sensor (TPS) (2)
- The mass air flow (MAP) sensor (1)
- The idle air control (IAC) valve (3)
13. Disconnect the ground terminal (5) from the intake collector.
14. Remove the clamp bracket (4) from the intake collector.





15. Disconnect the following electrical connectors:
- The manifold differential pressure (MDP) sensor
- The EVAP canister purge valve (2)
- The exhaust gas recirculation (EGR) valve (7)
16. Disconnect the following hoses:
- The PCV hose from the cylinder head cover (9)
- The breather hose from the throttle body (6)
- The EVAP canister purge valve hose (1)
- The water hose (8)
- The heater hoses (3,5)
17. Remove the EGR pipe (4).





18. Disconnect the following hoses:
- The heater hose (2)
- The EVAP canister hose (1)
- The fuel feed hose (4)
- The fuel return hose (3)
- The tank pressure control solenoid valve hose





19. Disconnect the hose (2) from the idle air control (IAC) valve.
20. Remove the idle air control (IAC) valve.
21. Remove the 4 nuts and 2 bolts on the intake collector.





22. Remove the intake collector (1) and throttle body (2) from the intake manifold (3) as an assembly.





23. If necessary, remove the 2 nuts and 2 bolts and remove the throttle (2) body from the intake collector (1).





24. Remove the 8 bolts and 4 nuts on the intake manifold.
25. Remove the intake manifold.

Installation Procedure





1. Install the new intake manifold gaskets (1) onto the cylinder heads.





Notice: Refer to Fastener Notice in Service Precautions.

2. Install the intake manifold. Secure the intake manifold with the 8 bolts and 4 nuts.
- Tighten the bolts and nuts to 23 Nm (16.5 ft. lbs.).





3. Install the new throttle body gasket to the intake collector.
4. Install the throttle body (2) to the intake collector (1). Secure the throttle body with the 2 bolts and 2 nuts.
- Tighten the nuts and bolts to 12 Nm (8.5 ft. lbs.).





5. Install the intake collector (1) and the throttle body (2) as an assembly to the intake manifold (3) with a new gasket. Secure with the 4 nuts and 2 bolts.
- Tighten the nuts and bolts to 12 Nm (8.5 ft. lbs.).





6. Install the idle air control (IAC) valve with a new gasket.
7. Connect the following hoses:
- The heater hose (2)
- The EVAP canister hose (1)
- The fuel feed hose (4)
- The fuel return hose (3)
- The tank pressure control solenoid valve hose





8. Install the exhaust gas recirculation (EGR) pipe (4)
9. Connect the following hoses:
- The PCV hose to the cylinder head cover (9)
- The breather hose to the throttle body (6)
- The EVAP canister purge valve hose (1)
- The water hose (8)
- The heater hoses (3,5)
10. Connect the following electrical connectors:
- The manifold differential pressure (MDP) sensor
- The EVAP canister purge valve (1)
- The exhaust gas recirculation (EGR) valve (2)





11. Install the clamp bracket (4) to intake collector.
12. Install the ground terminal (5) to intake collector.
13. Connect the following electrical connectors:
- The throttle position sensor (TPS) (2)
- The mass air flow (MAF) sensor (1)
- The idle air control (IAC) valve (3)





14. Connect the brake booster hose (2) to the intake manifold.
15. Connect the injector wire coupler (1).





16. Connect the water hoses (3) to the throttle body.
17. Connect the automatic transmission throttle cable (1) to the throttle body (automatic transmission only).
18. Connect the accelerator cable (2) to the throttle body.





19. Install the air cleaner upper case, the intake air hose, the intake air pipe (2) and the surge tank pipe (1) as one component.
20. Install the fuel injector sight shield.
21. Install the Front Suspension support brace.
22. Fill the cooling system.
23. Connect the negative battery cable.
- Tighten the bolt to 8 Nm (6 ft. lbs.).
24. Upon completion of the installation, start the engine and check for fuel and engine coolant leaks.