Intake Manifold: Service and Repair
INTAKE MANIFOLDREMOVAL
WARNING: NO FIRE, SPARKS OR SMOKING. STORE FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS, AND WEAR PROTECTIVE CLOTHING. Refer to FUEL SYSTEM - WARNING.
WARNING: DO NOT OPEN THE COOLING SYSTEM UNLESS THE COOLANT TEMPERATURE IS BELOW 90°C (194°F). OPEN RADIATOR CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS, WEAR PROTECTIVE CLOTHING AND EYE PROTECTION.
1. Disconnect the negative battery cable.
2. Drain coolant from the radiator.
3. Remove the engine cover.
4. Disconnect the engine wiring harness from inside the vehicle and carefully guide the harness into the engine compartment.
5. Disconnect the charge air hose at the intake manifold (Fig. 63).
6. Disconnect the EGR wiring harness connector (Fig. 63).
7. Remove the bolt retaining the engine wiring harness to the intake manifold (Fig. 63).
8. Disconnect the coolant hose at the connection junction through the intake manifold support bracket (Fig. 63).
NOTE: Collect and store any fluid spillage when disconnecting components.
9. Disconnect both fuel lines at the fuel filter (Fig. 63).
10. Remove the lower intake manifold support bracket (Fig. 63).
11. Remove the right intake manifold support brackets (Fig. 63).
12. Disconnect the fuel pressure sensor electrical connector (Fig. 63).
13. Raise and support the vehicle.
14. Remove the coolant hose at the rear of the intake manifold (Fig. 63).
15. Remove the rear intake manifold mounting bolts while accessible from below (Fig. 63).
16. Lower the vehicle.
17. Remove the remaining intake manifold bolts, lift the intake manifold up and out while guiding the engine wiring harness and fuel lines through the openings in the intake manifold, then remove the gasket.
NOTE: Install the EGR valve with new gasket onto the new intake manifold if the intake manifold is being replaced.
INSTALLATION
NOTE: If the intake manifold is being replaced, install the EGR valve with new gasket.
1. Clean both mating surfaces and install a new intake manifold gasket with the intake manifold. Guide the engine wiring harness and fuel lines through the intake manifold openings. Tighten manifold bolts to 16 Nm (142 inch lbs.) in a cross directional pattern beginning with the middle bolts and tightening outward to the ends.
2. Raise and support the vehicle.
3. Install the rear intake manifold bolts and tighten to 16 Nm (142 inch lbs.) (Fig. 63).
4. Install the rear coolant hose to the intake manifold and tighten clamp (Fig. 63).
5. Lower the vehicle.
6. Connect the fuel pressure sensor electrical connector (Fig. 63).
7. Install the right intake manifold support brackets. Tighten the bolts to 14 Nm (124 inch lbs.) (Fig. 63).
8. Install the lower intake manifold support bracket. Tighten bolts to 20 Nm (177 inch lbs.) (Fig. 63).
9. Connect both fuel lines to fuel filter assembly.
10. Connect the coolant hose at the connection junction above the lower intake manifold support bracket (Fig. 63).
11. Secure the engine wiring harness and cable duct to the intake manifold (Fig. 63).
12. Connect the EGR wiring harness connector (Fig. 63).
13. Connect the charge air hose to the intake manifold (Fig. 63).
14. Carefully route the engine wiring harness through and into the passenger compartment and reconnect.
15. Install the engine cover.
16. Fill the cooling system.
17. Connect the negative battery cable.
18. Start the engine and inspect for leaks. Care must be taken to observe the fuel system warning. Refer to FUEL SYSTEM - WARNING.