Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure

1. Remove the throttle body.
2. Remove the battery box.
3. Remove the oil level indicator and tube.




4. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (3).
5. Disconnect the MAP sensor wiring harness retainer (4) from the intake manifold.
6. Disconnect the positive crankcase ventilation (PCV) dirty air tube (2) from the camshaft cover.
7. Remove the generator.




8. Remove the engine wiring harness retainer from the engine wiring harness bracket.




9. Remove the 2 upper bolts securing the engine wiring harness bracket to the intake manifold.
10. Raise and support the vehicle only high enough to access the remaining components through the wheelhouse.
11. Remove the left front wheel.
12. Remove the left front wheelhouse liner.




13. Disconnect the following wiring harness retainers from the engine wiring harness bracket:
^ The battery cable
^ The engine (4, 6)
^ The MAP sensor (5)
14. Remove the remaining lower engine wiring harness bracket bolt. Remove the bracket from the engine compartment through the wheelhouse opening.




15. Remove the intake manifold bolts.
16. Lower the vehicle.
17. Remove the intake manifold from the cylinder head.
18. Remove and discard the seal from the intake manifold.
19. Mask off the open ports to the cylinder head, in order to prevent foreign objects from entering the engine.
20. Clean and inspect the intake manifold.

Installation Procedure

1. Remove the masking from the cylinder head and ensure the sealing surface is clean and dry.
2. Install a NEW seal into the intake manifold groove.




3. Position the intake manifold to the cylinder head.
4. Raise and support the vehicle only high enough to access the following components through the wheelhouse:
^ The intake manifold bolts
^ The engine wiring harness bracket bolts
^ The wiring harnesses

Notice: Refer to Fastener Notice.

5. Install the intake manifold bolts.

Tighten the bolts from the inside working outward to 10 N.m (89 lb in).




6. Position the engine wiring harness bracket to the engine and harnesses.
7. Install the engine wiring harness bracket bolts.

Tighten the bolts to 10 N.m (89 lb in).




8. Secure the following wiring harness retainers to the engine wiring harness bracket:
^ The battery cable
^ The engine (4, 6)
^ The MAP sensor (5)
9. Install the left front wheelhouse liner.
10. Install the left front wheel.
11. Lower the vehicle.




12. Connect the engine wiring harness retainer to the engine wiring harness bracket.
13. Install the generator.




14. Connect the PCV dirty air tube (2) to the camshaft cover.
15. Connect the MAP sensor wiring harness retainer (4) to the intake manifold.
16. Connect the MAP sensor electrical connector (3).
17. Install the oil level indicator and tube.
18. Install the battery box.
19. Install the throttle body.