Intake Manifold Removal

Intake Manifold Replacement

Removal Procedure

Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.





1. Disconnect the following electrical connectors:
^ Mass Airflow (MAP) sensor (1)
^ Intake Air Temperature (IAT) sensor (2)





2. Loosen the clamp at the air cleaner.
3. Remove the air cleaner bolts.
4. Remove the air cleaner.





5. Loosen the clamp (2) at the throttle body (1).
6. Remove the air cleaner duct (3).





7. Remove the coolant recovery reservoir bolt.
8. Reposition the coolant recovery reservoir to the side.
9. Remove the engine cover.
10. Relieve the fuel system pressure.





11. Remove the Oil fill tube bracket bolt and tube.





12. Remove the Air Conditioning (A/C) compressor bolts.





13. Disconnect the following A/C compressor electrical connectors:
^ A/C compressor (1)
^ A/C high pressure switch (2)
14. Reposition the A/C compressor.





15. Remove the Exhaust Gas Recirculation (EGR) valve pipe bolts (2) from the EGR valve.
16. Reposition the EGR valve pipe.





17. Disconnect the following electrical connectors:
^ Purge valve solenoid (1)
^ Ignition Coil harness (2)
^ Engine Coolant Temperature (ECT) sensor (3)
18. Remove the ECT sensor wire clip from the ignition coil harness.





19. Disconnect the following electrical connectors:
^ Manifold Absolute Pressure (MAP) sensor (1)
^ EGR valve (2)
20. Disconnect the vacuum hose from the rear of the intake manifold.





21. Disconnect the following electrical connectors:
^ Ignition Coil (1)
^ Throttle Position Sensor (TPS) (3)
^ Electronic Throttle Control (ETC) (4)
22. Remove the passenger rear, and the drivers front and rear harness clip bolts from the top of the intake manifold.
23. Open the passenger front harness clip. Remove the harness from the clip.
24. Reposition the engine wiring harness.





25. Disconnect the evaporative emission canister tube from the purge solenoid.





26. Disconnect the EVAP canister tube clip from the fuel rail.
27. Disconnect the EVAP canister tube from the canister.
28. Remove the EVAP canister tube.
29. Disconnect the fuel line quick connect fittings.





30. Remove the intake manifold bolts.

Important: Do not attempt to loosen the manifold by prying under the gasket surface with any tool.

31. Remove the intake manifold.





Important: The intake manifold gaskets are not reusable.

32. Remove and discard the intake manifold side gaskets.





33. Remove and discard the lower intake manifold end seals.





Important: The splash shield is secured using a snap-in fit. Do not distort the splash shield. The splash shield is reusable.

34. Remove the splash shield.





35. If replacement of the intake manifold is required, remove the throttle body nuts. Remove the throttle body and gasket.





36. If replacement of the intake manifold is required, remove the fuel pressure regulator vacuum hose.





37. If replacement of the intake manifold is required, remove the fuel rail studs and nuts. Remove the fuel rail and injectors.





38. If replacement of the intake manifold is required, remove the purge solenoid bolt and purge solenoid.





39. If replacement of the intake manifold is required, remove the MAP sensor bolt and sensor. Inspect the MAP sensor for damage.





40. If replacement of the intake manifold is required, remove the EGR valve nuts (1). Remove the EGR valve (2) and gasket (3). Discard the gasket.