Intake Manifold: Service and Repair

Intake Manifold





Intake Manifold - Cables and LH Connections









Intake Manifold - RH Connections









Intake Manifold - Rear Connections









Intake Manifold - Wiring Harness Retainers









Intake Manifold









Removal

1. Drain the engine cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.

2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.

3. Remove the 2 bolts and the Throttle Body (TB) shield.





4. Disconnect the acceleration control cable from the intake manifold and the TB.

5. If equipped, disconnect the speed control cable from the intake manifold and the TB.

6. Disconnect the Throttle Position (TP) sensor electrical connector.

7. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.

8. Disconnect the Idle Air Control (IAC) valve electrical connector.

9. Disconnect the vapor purge tube quick connect coupling. For additional information, refer to Fuel System - General Information Quick Connect Coupling.

10. Disconnect the engine vacuum harness, brake booster hose, the crankcase breather hose and the 2 coolant hoses.

11. Disconnect 2 engine wiring harness pin-type retainers from the intake manifold.

12. Disconnect the pin-type retainer from the rear of the intake manifold.

13. Remove the EGR tube support bracket bolt.

14. Remove the 2 bolts from the EGR tube flange.

15. Detach the fuel supply tube and the electrical connectors from the bracket and disconnect the Evaporative Emission (EVAP) tube quick connect coupling. For additional information, refer to Fuel System - General Information Quick Connect Coupling.

16. Disconnect the Knock Sensor (KS) electrical connector and disconnect the connector retainer from the intake manifold.

17. Remove the wiring harness pushpin from the bottom of the intake manifold.

18. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to Fuel System - General Information Spring Lock Couplings.

19. NOTICE: 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.

Remove the 5 bolts and the intake manifold.

- Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.

20. Remove and discard the 4 intake manifold gaskets.

Installation

1. 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.

Install 4 new intake manifold gaskets.

2. Position the intake manifold and install the 5 bolts.
- Tighten to 18 Nm (159 lb-in).

3. Connect the wiring pushpin to the bottom of the intake manifold.

4. Connect the KS connector retainer to the intake manifold and connect the electrical connector.

5. Attach the electrical connectors and the fuel supply tube to the bracket and connect the EVAP tube quick connect coupling. For additional information, refer to Fuel System - General Information Quick Connect Coupling.

6. Install the 2 EGR flange mounting bolts.
- Tighten to 18 Nm (159 lb-in).

7. Install the EGR tube support bracket bolt.
- Tighten to 10 Nm (89 lb-in).

8. Position the engine wiring harness and connect the 2 pin-type retainers.

9. Connect the engine vacuum harness, brake booster hose, the crankcase breather hose and the 2 coolant hoses.

10. Connect the IAC valve electrical connector and the fuel supply tube spring lock coupling. For additional information, refer to Fuel System - General Information Spring Lock Couplings.

11. Connect the MAP sensor electrical connector.

12. Connect the TP sensor electrical connector.

13. Connect the acceleration control cable to the intake manifold and the TB.

14. If equipped, connect the speed control cable to the intake manifold and the TB.

15. Position the TB shield and install the 2 bolts.
- Tighten to 8 Nm (71 lb-in).





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

17. Fill and bleed the engine cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.