Intake Manifold Replacement
INTAKE MANIFOLDREMOVE OR DISCONNECT
1. Negative battery cable.
Fig. 5 Intake Manifold Top Cover Tightening Sequence:
2. Intake manifold sight shield - four nuts.
3. Relieve fuel system pressure.
4. Air intake duct from throttle body.
5. Transaxle vent hose and transaxle shift cable at bracket.
6. Throttle Position Sensor (TPS) and Idle Air Control (IAC) valve connectors.
7. Accelerator cable and cruise control cable at throttle body.
8. Front bank spark plug wires and lay aside.
9. Throttle body coolant hoses at throttle body and surge tank pipe.
10. EGR pipe and crankcase ventilation pipe at throttle body spacer.
11. Brake booster vacuum hose at intake manifold vacuum fitting.
12. Fuel rail ground wire at rear cylinder head.
13. Quick-connect fittings at fuel rail.
a. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within fitting.
CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.
b. Using compressed air blow dirt out of fitting.
c. Choose correct tool from J 37088-A tool set for size of fitting. Insert tool into female connector, then push/pull inward to release locking tabs.
d. Pull connection apart.
CLEAN
- Using a clean shop towel. wipe off male pipe end
- Inspect both ends of fitting for dirt and burrs. Clean or replace components/assemblies as required.
14. Disconnect fuel rail bracket at EGR valve.
15. Disconnect PCV hose at intake manifold.
16. Disconnect injector harness main connector.
Fig. 6 Intake Manifold Bolts/Studs:
17. Remove six bolts, four studs and intake manifold.
IMPORTANT: The intake manifold carrier gaskets are attached to the intake manifold through a snap-lock feature. When removing the intake manifold, the carrier gaskets will remain attached to the manifold.
IF REPLACING INTAKE MANIFOLD
DISASSEMBLE
1. Remove fuel rail.
2. Remove intake manifold carrier gaskets from intake manifold.
IMPORTANT: DO NOT replace the intake manifold gaskets after intake manifold removal. The gaskets are reusable. Gasket should only be replaced if the plastic housing or rubber seals are damaged.
3. Remove throttle body.
4. Remove Manifold Absolute Pressure (MAP) Sensor.
CLEAN
- Throttle body 0-ring sealing surfaces.
- Intake manifold sealing surfaces.
ASSEMBLE
1. Install MAP sensor.
2. Install throttle body.
3. Install intake manifold carrier gaskets.
4. Install fuel rail.
INSTALL OR CONNECT
1. Intake Manifold, six bolts and four studs.
IMPORTANT: When tightening intake manifold bolts and studs, start at the center of the manifold and work your way outward in a circular pattern.
TIGHTEN
- Bolts and studs to 10 Nm (89 lb. in.)
IMPORTANT: Only tighten the intake manifold bolts when the engine and manifold are cool. DO NOT tighten the intake manifold bolts and studs with the engine at operating temperature.
2. Injector harness main connector.
3. PCV lines at intake manifold.
4. Fuel rail bracket at EGR valve.
5. Quick connect fittings to fuel rail.
a. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet tubes.
b. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
c. Once installed, pull on both sides of fitting to make sure connection is secure.
6. Fuel rail ground wire at rear cylinder head.
7. Brake booster vacuum hose at intake manifold vacuum fitting.
8. EGR pipe and crankcase ventilation pipe at throttle body spacer.
TIGHTEN
- EGR pipe bolt to 28 Nm (21 lb. ft.)
9. Throttle body coolant hoses at throttle body and surge tank pipe.
10. Front bank spark plug wires.
11. Accelerator cable and cruise control cable at throttle body.
12. TP sensor and IAC valve connectors.
13. Transaxle vent hose and transaxle shift cable at bracket.
14. Air intake duct.
15. Fuel filler cap.
16. Negative battery cable.
CLEAN
- Turn ignition switch to the "ON" position for ten seconds, then turn to the "OFF" position for ten seconds. Again turn to the "ON" position and check for fuel leaks.
17. Intake manifold sight shield - four nuts.
TIGHTEN
^ Nuts to 3 Nm (27 lb. in.)