Intake Manifold: Service and Repair

Intake Manifold

Removal

1. With vehicle in NEUTRAL, position it on a hoist. REFER to Jacking and Lifting .

2. Loosen the 4 retainers and remove the underbody shield.





3. Disconnect the battery ground cable. REFER to Battery Disconnect .

4. Disconnect the EVAP (Evaporative Emission) tube from the CAC (Charge Air Cooler) outlet tube. REFER to Quick Connect Coupling .

- Loosen the clamp and disconnect the CAC (Charge Air Cooler) outlet tube from the TB (Throttle Body).






5. Disconnect the FRP (Fuel Rail Pressure) sensor and MAP (Manifold Absolute Pressure) sensor electrical connectors.

- Detach the 2 EVAP (Evaporative Emission) tube retainers from the intake manifold.
- Detach the heater hose from the retaining clip.






6. Disconnect the EVAP (Evaporative Emission) tube from the EVAP (Evaporative Emission) canister purge valve and the ACL (Air Cleaner) outlet pipe. REFER to Quick Connect Coupling .

- Disconnect the EVAP (Evaporative Emission) canister purge valve electrical connector.
- Remove the engine appearance cover mounting stud.
- Remove the EVAP (Evaporative Emission) canister purge valve and EVAP (Evaporative Emission) tube assembly.






7. Detach the 2 fuel tube retaining clips from the intake manifold.





8. Disconnect the 2 vacuum hoses from the intake manifold.

- Disconnect the vacuum tube quick connect coupling. REFER to Quick Connect Coupling .
- Detach the vacuum hose retainer from the intake manifold.






9. Depress the red quick connect locking ring and pull the vacuum tube out of the quick connect fitting.

- Remove the 5 intake manifold bolts and position the intake manifold forward.






10. Disconnect the TB (Throttle Body) electrical connector and detach the wiring harness retainer from the TB (Throttle Body).

- Detach the 2 KS (Knock Sensor) wiring harness retainers from the intake manifold.
- Disconnect the crankcase ventilation oil separator tube and remove the intake manifold.






Installation

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.

1. Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.





2. Position the intake manifold and connect the crankcase ventilation oil separator tube.

- Attach the 2 KS (Knock Sensor) wiring harness retainers from the intake manifold.
- Connect the TB (Throttle Body) electrical connector and attach the wiring harness retainer to the TB (Throttle Body).






3. Install the intake manifold and the 5 bolts.
- Tighten in the sequence shown to 20 Nm (177 lb-in).

- Install the vacuum tube into the quick connect coupling.






4. Connect the 2 vacuum hoses to the intake manifold.

- Connect the vacuum tube quick connect coupling. REFER to Quick Connect Coupling .
- Attach the vacuum hose retainer to the intake manifold.






5. Attach the 2 fuel tube retaining clips to the intake manifold.





6. Install the EVAP (Evaporative Emission) canister purge valve and EVAP (Evaporative Emission) tube assembly.

- Install the engine appearance cover mounting stud.
- Tighten to 5 Nm (44 lb-in).

- Connect the EVAP (Evaporative Emission) canister purge valve electrical connector.
- Connect the EVAP (Evaporative Emission) tube to the EVAP (Evaporative Emission) canister purge valve and the ACL (Air Cleaner) outlet pipe. REFER to Quick Connect Coupling .






7. Connect the FRP (Fuel Rail Pressure) sensor and MAP (Manifold Absolute Pressure) sensor electrical connectors.

- Attach the 2 EVAP (Evaporative Emission) tube retainers to the intake manifold.
- Attach the heater hose to the retaining clip.






8. Connect the CAC (Charge Air Cooler) outlet tube to the TB (Throttle Body).
- Tighten the clamp to 5 Nm (44 lb-in).

- Connect the EVAP (Evaporative Emission) tube to the CAC (Charge Air Cooler) outlet tube. REFER to Quick Connect Coupling .






9. Install the underbody shield and the 4 retainers.





10. Connect the battery ground cable. REFER to Battery Disconnect .