Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure





Caution:
Refer to Battery Disconnect Caution Battery Disconnect Caution in Cautions and Notices.

1. Remove the fuel pump fuse.

2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.

3. Disconnect the negative battery cable.

4. Drain the engine coolant. Refer to Cooling System Draining and Filling (2.5L) Service and Repair.





5. Remove the engine beautification cover retaining nut and engine beautification cover.

6. Remove the air filter snorkel.





7. Remove the variable intake system (VIS) vacuum tank.





8. Remove the fuel pressure regulator.





9. Remove the breather hose.

10. Remove the PCV vacuum hose.





11. Remove the air filter outlet hose.

12. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement Removal and Replacement in Engine Controls-2.5L.





13. Disconnect the charcoal canister purge solenoid connector and hose.

14. Disconnect the heated oxygen sensor (HO2S) connector.

15. Disconnect the manifold absolute pressure (MAP) sensor connector.

16. Disconnect the crankshaft position (CKP) sensor connector.





17. Disconnect the exhaust gas recirculation (EGR) solenoid connector.

18. Disconnect the camshaft position (CMP) sensor connector.

19. Remove the intake air temperature (IAT) sensor.

20. Disconnect the ignition coil connector.

21. Remove the vacuum hose on the brake booster.





22. Remove the EGR pipe from the intake manifold.

23. Remove the engine coolant temperature (ECT) sensor.





24. Remove the wiring harness from the support bracket on the cylinder block.





25. Remove the intake manifold retaining nuts/bolts and the intake manifold.

26. Remove the bolts on the intake manifold support bracket.

27. Remove the intake manifold gaskets.

28. Clean the contact surfaces between intake manifold and the cylinder head.

Important:
Remove the fuel rail after removing the intake manifold.


Installation Procedure





1. Discard used intake manifold gaskets and install new ones.

Important:
Install the intake manifold after installing the fuel rail.


2. Install the intake manifold.

Notice:
Refer to Fastener Notice Fastener Notice in Cautions and Notices.

3. Install the intake manifold retaining nuts and bolts.

* Tighten the 7 intake manifold retaining bolts to 12 Nm (106 lb in).

* Tighten the 4 intake manifold retaining nuts to 12 Nm (106 lb in).

4. Install the intake manifold support bracket.

Tighten the 2 bolts on the intake manifold support bracket to 12 Nm (106 lb in).





5. Install the wiring harness to the supporting bracket on the cylinder block.

6. Install the ECT sensor.





7. Install the EGR pipe to the intake manifold.

8. Install the intake EGR pipe retaining bolts on the intake manifold.

Tighten the intake EGR pipe retaining bolts to 10 Nm (89 lb in).





9. Install the vacuum hose to the brake booster.

10. Connect the ignition coil connector.

11. Install the IAT sensor.

Tighten the IAT sensor to 25 Nm (18 lb in).

12. Connect the CMP sensor connector.

13. Connect the EGR solenoid connector.





14. Connect the CKP sensor connector.

15. Connect the MAP sensor connector.

16. Connect the HO2S connector.

17. Connect the charcoal canister purge solenoid connector and hose.





18. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement Removal and Replacement in Engine Controls-2.5L.

Tighten the throttle body assembly retaining bolts to 13 Nm (115 lb in).





19. Install the PCV vacuum hose.

20. Install the breather hose.





21. Install the fuel pressure regulator. Refer to Fuel Pressure Regulator Replacement Service and Repair in Engine Controls-2.5L.

Tighten the fuel pressure regulator retaining bolts to 12 Nm (106 lb in).





22. Install the VIS vacuum tank. Refer to Intake Air Tuning Valve Vacuum Reservoir Replacement Service and Repair in Engine Controls-2.5L.

Tighten the VIS vacuum tank retaining bolts to 8 Nm (71 lb in).





23. Install the air filter snorkel.

Tighten the air filter snorkel retaining bolts to 6 Nm (53 lb in).





24. Install the engine beautification cover.

Tighten the engine beautification retaining bolts to 10 Nm (89 lb in).

25. Install the fuel pump fuse.

26. Connect the negative battery cable.

27. Refill the engine cooling system. Refer to Cooling System Draining and Filling (2.5L) Service and Repair.