Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure





1. Disconnect the Intake Air Temperature (IAT) sensor connector.
2. Loosen the clamp at the air cleaner assembly.
3. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
4. Loosen the clamp at the throttle body assembly.
5. Disconnect the PCV fresh air vent hose at the outlet duct assembly.
6. Remove the outlet resonator/duct assembly.





Important: The mating surfaces between the throttle body to manifold and manifold to cylinder head should be free from dirt and foreign material before servicing.

7. Cover the throttle body opening with a shop towel and use the shop air to remove any dirt at the base of the throttle body to intake and intake manifold to cylinder head.





8. Disconnect the harness connector at the throttle body.





9. Remove the throttle body bolts.
10. Remove the throttle body.
11. Remove the throttle body gasket.





Notice: Cover the intake manifold opening with a shop towel whenever the throttle body is removed to prevent foreign material entry.

12. Block the intake manifold opening with a clean shop towel to prevent dirt from entering.





13. Remove the Engine Control Module (ECM) bolts and set the ECM aside.
14. Disconnect the electrical connectors (injector harness) attach to the side of the manifold and position the harness away from the manifold and set aside.
15. Disconnect the Manifold Absolute Pressure (MAP) sensor.
16. Disconnect the purge hose.
17. Disconnect the electrical attachment bolt at bottom of the manifold.
18. Raise the vehicle.
19. Disconnect the electrical harness clips at the bottom of the manifold.
20. Lower the vehicle.





21. Remove the oil level tube bolt and rotate tube away from the manifold.
22. Remove the intake manifold bolts and nuts.
23. Pull the manifold away from the cylinder head.





24. Disconnect the brake booster hose at the manifold by releasing the white tab.
25. Remove the intake manifold assembly.





Important: The intake manifold gasket is not reusable.

26. Remove the intake manifold gasket and discard.

Notice: Cover the cylinder head ports with a shop towel to prevent foreign material from entering the cylinder head.

27. Block the intake manifold to cylinder head openings with a clean shop towel to prevent dirt from entering.

Installation Procedure





1. Remove the shop towel from the throttle body opening.
2. Install the intake manifold gasket to manifold.





3. Connect the brake booster hose to intake manifold.
4. Install the intake manifold to cylinder head.

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the intake manifold bolts and nuts.
^ Tighten the intake manifold-to-cylinder head bolts L61 to 10 Nm (89 inch lbs.).
^ Tighten the intake manifold-to-cylinder head nuts L61 to 10 Nm (89 inch lbs.).





6. Install the oil level indicator tube assembly and bolt.
^ Tighten the oil level indicator tube-to-intake manifold bolt L61 to 10 Nm (89 inch lbs.).





7. Install the ECM assembly and bolts.
8. Attach the electrical harness to the bottom of the intake manifold.
9. Connect the electrical connector at the ECM, injector harness and MAP sensor.





10. Connect the purge hose.
11. Remove the shop towel from the throttle body opening.





12. Install the new throttle body gasket.
13. Install the throttle body assembly and bolts.
^ Tighten the throttle body-to-intake manifold bolts L61 to 10 Nm (89 inch lbs.).





14. Connect the throttle body electrical connector.





15. Position the outlet resonator/duct assembly into position.
16. Connect the PCV fresh air vent hose assembly.
17. Tighten the clamp at the throttle body assembly.
18. Position the outlet resonator/duct assembly up with support bracket and install the push-pin.





19. Tighten the clamp at the air cleaner assembly.
20. Connect the Intake Air Temperature (IAT) sensor connector.