Intake Manifold: Service and Repair

Intake Manifold











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. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction.
2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
3. Remove the fuel rail and injectors. For additional information, refer to Fuel Delivery and Air Induction.
4. Disconnect the electronic throttle body (TB) electrical connector.
5. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
6. Disconnect the throttle position (TP) sensor electrical connector.
7. Disconnect the PCV hose from the heated PCV fitting on the intake manifold.
8. Remove the bolts and position the heated PCV fitting aside.
^ Remove and discard the O-ring seal.
9. Detach the wiring harness retainers from the intake manifold.
10. Disconnect the charge motion control valve (CMCV) electrical connector.
11. Remove the bolts and position the intake manifold forward.
12. Disconnect the brake booster vacuum hose from the rear of the intake manifold.
13. Disconnect the vacuum hose from the rear of the intake manifold.
14. Remove the intake manifold and the gaskets.
^ Discard the 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 gaskets.

NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at the rear of the intake manifold. Use extreme care during the installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.

Using new intake manifold gaskets, position the intake manifold.
2. Connect the vacuum hose to the rear of the intake manifold.
3. Connect the brake booster hose to the rear of the intake manifold.
4. Install the intake manifold bolts and tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 2 Nm (18 lb-in).
^ Stage 2: Tighten to 10 Nm (89 lb-in).





5. Connect the CMCV electrical connector.
6. Attach the wiring harness retainers to the intake manifold.
7. Install a new O-ring seal, position the heated PCV fitting and install the bolts.
8. Connect the PCV hose to the heated PCV fitting on the intake manifold.
9. Connect the TP sensor electrical connector.
10. Connect the EVAP hose to the intake manifold.
11. Connect the electronic TB electrical connector.
12. Install the fuel rail and injectors.
13. Install the air cleaner outlet pipe.