Intake Manifold: Service and Repair

Intake Manifold

Intake Manifold Connections









Intake Manifold









Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.

2. Disconnect the battery ground cable. For additional information, refer to Battery.

3. Detach the Knock Sensor (KS) electrical connector from the intake manifold.

4. Disconnect the PCV tube from the intake manifold.

5. Disconnect the brake booster vacuum hose from the intake manifold.

6. Disconnect the main vacuum harness fitting from the intake manifold.

7. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.

8. Disconnect the EGR system module electrical connector.

9. Detach the wiring harness retainer.

10. Disconnect the EGR system module vacuum fitting.

11. Loosen the fitting and disconnect the exhaust manifold-to-EGR system module tube from the EGR system module.
- To install, tighten to 34 Nm (25 lb-ft).

12. Disconnect the Throttle Position (TP) sensor electrical connector.

13. Disconnect the Electronic Throttle Body (ETB) electrical connector.

14. Remove the nut and detach the wiring harness bracket from the ETB.
- To install, tighten to 9 Nm (80 lb-in).

15. Remove the 8 bolts, the intake manifold and the 6 gaskets.
- To install, tighten to 11 Nm (97 lb-in).

16. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths. Use a plastic scraping tool to remove all traces of the old intake manifold gaskets.

Clean the sealing surfaces and inspect the gaskets. Install new gaskets if necessary.

17. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

To install, reverse the removal procedure.