Removal and Replacement

Intake Manifold

Material:

EGR System Module Tube, PCV Tube, Electrical and Vacuum Connections (Part 1):

EGR System Module Tube, PCV Tube, Electrical and Vacuum Connections (Part 2):

Intake Manifold and Gaskets (Part 1):

Intake Manifold and Gaskets (Part 2):

Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Disconnect the fuel hose spring lock coupling. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Drain the cooling system. For additional information, refer to Cooling System.
4. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
5. Remove the ignition coils. For additional information, refer to Ignition System.
6. Remove the generator. For additional information, refer to Alternator.
7. Remove the EGR system module tube.
8. Disconnect the EGR system module electrical connector.
9. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to Fuel Delivery and Air Induction.
10. Disconnect the electronic throttle control electrical connector.
11. Disconnect the fuel rail pressure and temperature sensor electrical connector.
12. Disconnect the fuel rail pressure and temperature sensor vacuum connector.
13. Disconnect the 8 fuel injector electrical connectors.
14. Disconnect the vacuum and coolant hose and plug the coolant hose.





15. Disconnect the brake booster vacuum hose and the evaporative emissions (EVAP) hose quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





16. Disconnect the upper radiator coolant hose and position aside.





17. Disconnect the heater coolant hose and position aside.





18. Remove the 3 power steering reservoir support bracket bolts and the power steering reservoir support bracket.





19. Disconnect the vacuum hose.





20. Remove the 2 thermostat housing bolts and the thermostat housing and discard the O-ring seal.
21. Remove the thermostat.
22. Remove the 9 intake manifold bolts.
23. Remove the intake manifold and discard the RH and LH intake manifold 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 remove all traces of old sealant.

Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover. Follow the directions on the packaging.
2. Install the intake manifold in the following sequence.
1 Position the new intake manifold gaskets.
2 Position the intake manifold.
3 Loosely install the 9 intake manifold bolts.
3. Tighten the intake manifold bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).





4. Install the thermostat.
5. Install the thermostat housing and a new thermostat housing O-ring seal.
6. Install the 2 thermostat housing bolts.
^ Tighten to 25 Nm (18 lb-ft).
7. Connect the fuel hose spring lock coupling. Release the fuel system pressure.
8. Connect the vacuum hose.





9. Install the power steering reservoir support bracket and the 3 bolts.
^ Tighten the 2 bracket-to-power steering reservoir bolts to 17 Nm (13 lb-ft).
^ Tighten the power steering reservoir bracket-to-thermostat housing bolt to 11 Nm (8 lb-ft).





10. Connect the heater coolant hose.





11. Connect the upper radiator coolant hose.





12. Connect the electronic throttle control electrical connector.
13. Connect the fuel rail pressure and temperature sensor electrical connector.
14. Connect the fuel rail pressure and temperature sensor vacuum connector.
15. Connect the 8 fuel injector electrical connectors.
16. Connect the vacuum and coolant hose.





17. Connect the brake booster vacuum hose and the EVAP hose quick connect coupling.





18. Install the EGR system module tube.
^ Tighten to 40 Nm (30 lb-ft).
19. Connect the EGR system module electrical connector.
20. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction.
21. Install the ignition coils.
22. Install the generator.
23. Install the air cleaner outlet pipe.
24. Connect the battery ground cable. For additional information, refer to Battery.
25. Fill and bleed the engine cooling system.