Intake Manifold: Service and Repair

Intake Manifold

Material:

Removal

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

1. Release the fuel system pressure.
2. Drain the engine cooling system.
3. Drain the supercharger (SC) cooling system.
4. Remove the 4 nuts and the strut tower cross brace.





5. Remove the air cleaner outlet pipe.
6. Disconnect the battery ground cable.
7. Remove the exhaust gas recirculation (EGR) tube.
8. Disconnect the throttle position (TP) sensor electrical connector.
9. Remove the 4 bolts and position the throttle body (TB) and spacer assembly aside.
10. Disconnect the intake air temperature 2 (IAT2) sensor electrical connector.
11. Disconnect the fuel supply tube.
12. Disconnect the 4 LH fuel injector electrical connectors.
13. Remove the 2 bolts and the wiring harness retainer from the rear of the intake manifold.
14. Detach the 2 wiring harness pin-type retainers from the rear of the intake manifold.
15. Disconnect the fuel rail pressure and temperature sensor electrical connector.
16. Disconnect the 4 RH fuel injector electrical connectors.
17. Disconnect the EGR system module electrical connector.
18. Disconnect the crankcase ventilation tube from the RH side of the SC.
19. Disconnect the SC bubbler hose from the rear of the SC.
20. Rotate the SC drive belt tensioner clockwise and remove the drive belt from the SC drive pulley.





21. Disconnect the 2 upper radiator hoses and the 2 coolant vent hoses from the intake manifold.
22. Disconnect the 2 coolant hoses from the charge air cooler (CAC).
23. Disconnect the heater hose located below the rear of the intake manifold.
24. Remove the 14 bolts and the intake manifold assembly.
- Discard the gaskets.

Installation

1. NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

Using new intake manifold gaskets, position the intake manifold.
2. Install the 14 bolts.
- Tighten in the sequence shown to 10 Nm (89 inch lbs.).





3. Connect the heater hose located below the rear of the intake manifold.
4. Connect the 2 coolant hoses to the (CAC).
5. Connect the 2 upper radiator hoses and the 2 coolant vent hoses to the intake manifold.
6. Rotate the SC drive belt tensioner clockwise and install the drive belt onto the SC drive pulley.





7. Connect the SC bubbler hose to the rear of the SC.
8. Connect the crankcase ventilation tube to the RH side of the SC.
9. Connect the EGR system module electrical connector.
10. Connect the 4 RH fuel injector electrical connectors.
11. Connect the fuel rail pressure and temperature sensor electrical connector.
12. Attach the 2 wiring harness pin-type retainers to the rear of the intake manifold.
13. Install the wiring harness retainer and the 2 bolts onto the rear of the intake manifold.
14. Connect the 4 LH fuel injector electrical connectors.
15. Connect the fuel supply tube.
16. Connect the IAT2 sensor electrical connector.
17. Install the TB and spacer assembly and the 4 bolts.
- Tighten to 10 Nm (89 inch lbs.).
18. Connect the TP sensor electrical connector.
19. Install the EGR tube.
20. Install the air cleaner outlet pipe.
21. Connect the battery ground cable.
22. Install the strut tower cross brace and the 4 nuts.
- Tighten to 35 Nm (26 ft. lbs.).





23. Fill and bleed the SC cooling system.
24. Fill and bleed the engine cooling system.