Intake Manifold: Service and Repair

Intake Manifold

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Exploded View

Intake Manifold









Removal

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Lifting Points .

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

3. Remove the 8 retainers and the underbody insulator.





4. Detach the 2 KS (Knock Sensor) electrical connectors from the intake manifold.

- Detach the wiring harness retainer from the intake manifold.






5. Remove the intake manifold lower bolt.





6. Detach the electrical connector and the wiring harness pin-type retainer from the RH (Right Hand) upper side of the intake manifold.





7. Remove the ACL (Air Cleaner) outlet tube. REFER to Air Cleaner Outlet Pipe - 2.0L GDI .

8. Disconnect the TB (Throttle Body) electrical connector and the wiring harness retainer.

- Detach the wiring harness pin-type retainer from the lower LH (Left Hand) side of the intake manifold.






9. Disconnect the fuel vapor tube quick connect coupling from the intake manifold. REFER to Quick Connect Coupling - Type 1 .





10. Disconnect the brake booster vacuum tube from the intake manifold.





11. Remove the 5 remaining upper intake manifold bolts.

- Position back the intake manifold to allow access to disconnect the crankcase ventilation oil separator tube from the intake manifold.
- 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. Inspect and install new intake manifold gaskets if necessary.





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

- Install the 5 upper intake manifold bolts finger tight.






3. Install the intake manifold lower bolt finger tight.





4. Tighten the 6 intake manifold bolts in the sequence shown.
- Tighten to 20 Nm (177 lb-in).






5. Connect the brake booster vacuum tube to the intake manifold.





6. Connect the fuel vapor tube quick connect coupling to the intake manifold. REFER to Quick Connect Coupling - Type 1 .





7. Connect the TB (Throttle Body) electrical connector and the wiring harness retainer.

- Attach the wiring harness pin-type retainer to the lower LH (Left Hand) side of the intake manifold.






8. Install the ACL (Air Cleaner) outlet tube. REFER to Air Cleaner Outlet Pipe - 2.0L GDI .

9. Attach the electrical connector and the wiring harness pin-type retainer to the RH (Right Hand) upper side of the intake manifold.





10. Attach the 2 KS (Knock Sensor) electrical connectors to the intake manifold.

- Attach the wiring harness retainer to the intake manifold.






11. Position the underbody insulator and install the 8 retainers.





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