Intake Manifold: Service and Repair

INTAKE MANIFOLD
REMOVAL
1. Disconnect the negative battery cable.
2. Remove the air cleaner housing.
3. Remove the mass air flow sensor.
4. Remove the fuel rail with fuel injectors.
5. Disconnect the vacuum lines to the EGR valve, brake booster, crankcase ventilator and purge valve from the intake manifold.
6. Disconnect the engine harness connectors.





7. Disconnect the EGR pipe (1) at the EGR valve (2).





8. Remove the air pump switchover valves (4).
9. Remove the bolts, the intake manifold (1) and the gaskets (2).

INSTALLATION
1. Clean the gasket surfaces of the cylinder heads and the intake manifold.





2. Position the intake manifold (1) on the cylinder heads with new gaskets (2) in place.
3. Install the intake manifold bolts and tighten to 20 Nm (15 ft. lbs.).
4. Install the air pump switchover valves (4). Tighten the bolts to 20 Nm (15 ft. lbs.).





5. Connect the EGR pipe fitting (1) to the EGR valve (2). Tighten the EGR pipe fitting to 40 Nm (30 ft. lbs.).
6. Install the mass air flow sensor.
7. Connect the engine harness connectors.
8. Connect the vacuum lines at the crankcase ventilator, purge valve, EGR valve, and the brake booster.
9. Install the fuel rail with fuel injectors.
10. Install the air cleaner housing.
11. Connect the negative battery cable.
12. Start the engine and check for leaks.