Intake Manifold: Service and Repair

INTAKE MANIFOLD

Removal

WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components to prevent possible injury. Failure to follow these instructions may result in personal injury.


1. Remove the fuel injection supply manifold. Refer to FUEL INJECTION SUPPLY MANIFOLD.




2. Disconnect the throttle position (TP) sensor electrical connector.




3. Disconnect the idle air control (IAC) electrical connector and unclip the harness from the bracket.





4. Disconnect the main engine control sensor wiring. Remove the connector from the mounting bracket.




5. Disconnect the powertrain control module (PCM) wire harness from the bracket.




6. Disconnect the heated oxygen sensor (HO2S) wiring harness from the bracket.




7. Remove the HO2S wiring harness retainer.




8. Disconnect the cylinder head temperature (CHT) sensor electrical connector.




9. Detach the CHT sensor wiring harness from the clip, and remove the clip.




10. Disconnect the brake booster vacuum supply hose.




11. Disconnect the four vacuum hoses.




12. Disconnect the positive crankcase ventilation (PCV) vacuum hose.

13. Remove the generator. Refer to GENERATOR - 2.0L.





14. Remove the exhaust gas recirculation (EGR) valve bolts.

NOTE: Illustration shown with throttle body removed for clarity.




15. Remove the intake manifold.
- Remove the two nuts and five bolts in the sequence shown.

16. Remove and inspect the intake manifold gaskets.
- Discard if damaged.

Installation




NOTE: Illustration shown with the throttle body removed for clarity.

NOTE: Install new intake manifold gaskets if damaged.

1. Install the intake manifold and tighten using the sequence shown.

NOTE: The EGR valve sealing surfaces are soft metals. Carefully clean all sealing surfaces and install a new EGR valve gasket.




2. Install the EGR valve bolts.
3. Install the generator. Refer to GENERATOR - 2.0L.




4. Connect the PCV vacuum hose.




5. Connect the four vacuum hoses.




6. Connect the brake booster vacuum supply hose to the intake manifold.




7. Install the CHT sensor wiring clip and attach the CHT wiring harness.




8. Connect the CHT sensor.




9. Install the retainer for the HO2S wiring harness mount.




10. Connect the HO2S sensor wiring harness to the bracket.




11. Connect the PCM wire harness to the bracket.




12. Connect the main engine control sensor wiring.




13. Connect the IAC electrical connector and reattach the harness to the bracket.




14. Connect the throttle position TP sensor electrical connector.
15. Install the fuel injection supply manifold. Refer to FUEL INJECTION SUPPLY MANIFOLD.