Intake Manifold Replacement

FUEL SYSTEM PRESSURE RELEASE PROCEDURE

WARNING: Release fuel system pressure before servicing system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle.

REMOVAL
1. Perform fuel system pressure release procedure before attempting any repairs.

Auxiliary Jumper Terminal:

2. Disconnect negative cable from auxiliary jumper terminal.
3. Remove Air Inlet Resonator.
4. Disconnect the fuel supply line quick connect at the fuel rail assembly.

WARNING: Wrap shop towels around hose to catch any gasoline spillage.

5. Remove fuel rail assembly attaching screws and remove fuel rail assembly from engine. Cover injector holes with a suitable covering.

CAUTION: Do not set fuel injectors on their tips, damage may occur to the injectors
6. Remove accelerator, kickdown and speed control cables from throttle lever and bracket.

Idle Air Control (IAC) Motor, Throttle Position Sensor (TPS) Wiring Connectors, And Vacuum Hose Connection:

7. Disconnect idle air control (IAC) motor and throttle position sensor (TPS) wiring connectors.

Intake Air Temperature Sensor, Leak Detection Pump, And PCV Hoses - 2.4L Engine:

8. Disconnect intake air temperature sensor, leak detection pump and PCV hoses.

Intake Manifold Electrical Connectors And Vacuum Hose Connections - 2.0L Engine:

Manifold Absolute Pressure (MAP), Vapor Canister, And Brake Booster Hoses - 2.4L Engine:

9. Disconnect intake air temperature electrical connector. Disconnect leak detection pump and PCV hoses.
10. Disconnect knock sensor electrical connector and disconnect wiring harness from tab located on the intake manifold.
11. Remove transaxle to throttle body support bracket fasteners at the throttle body and loosen the fastener at the transaxle end.

Tube Assembly - Typical:

12. Remove EGR tube bolts at the valve and at the intake manifold. Remove tube from engine.

Intake Manifold Tightening Sequence - 2.0L Engine:

Intake Manifold Tightening Sequence - 2.4L Engine:

13. Remove the intake manifold to inlet water tube support fastener.
14. Remove intake manifold fasteners and washer assemblies. Remove intake manifold.

INSTALLATION

Intake Manifold O-Rings - 2.0L Engine:

Replace all O-ring seals, and all intake manifold fasteners and washers are to be discarded and replaced with NEW fasteners and washers.

Intake Manifold Tightening Sequence - 2.0L Engine:

1. Install new intake manifold O-rings, and tighten fasteners to 11.9 Nm (105 inch lbs.) in sequence shown.
2. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 inch lbs.).
3. Connect PCV and brake booster hoses.
4. Inspect quick connect fittings for damage, replace if necessary. Lubricate tube with clean engine oil. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
5. Install throttle body. Tighten fastener to 22 Nm (200 inch lbs.). Install transaxle to throttle body support bracket and tighten to 12 Nm (105 inch lbs.) at the throttle body first. Next tighten the bracket at the transaxle.
6. Connect manifold absolute pressure (MAP) and intake air temperature sensor wiring connectors.
7. Connect knock sensor electrical and starter relay connectors. Connect wiring harness to intake manifold tab.
8. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.
9. Connect vacuum hoses to throttle body.
10. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever.
11. Loosely assemble the EGR tube onto valve and intake manifold finger tight. Tighten tube fasteners at the EGR valve first to 11 Nm (95 inch lbs.). Then, tighten the intake manifold side fasteners to 11 Nm (95 inch lbs.).
12. Connect negative cable to auxiliary jumper terminal.
13. With the DRB scan tool use ASD Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.