Intake Manifold: Service and Repair
Intake ManifoldRemoval
1. Disconnect the battery ground cable.
2. Drain the engine cooling system.
3. Remove the air cleaner and outlet pipe.
4. Disconnect the fuel spring lock coupling.
5. Remove the wiper mounting arm and pivot shaft.
6. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.
7. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.
8. Remove the bolts and the exhaust gas recirculation (EGR) tube heat shield.
9. Disconnect the electrical connector and the vacuum hoses.
10. Disconnect the evaporative emissions (EVAP) canister purge valve vacuum hoses.
11. Disconnect the generator electrical connector.
12. Remove the bolts and the generator mounting bracket.
13. Disconnect the upper radiator hose.
14. Disconnect the throttle control and the throttle position (TP) sensor electrical connectors.
15. Disconnect the heater hose.
16. Disconnect the EGR system module tube nut from the EGR system module.
17. Remove the nut at the exhaust manifold and remove the EGR tube.
18. Separate the fuel charging wiring pin-type retainer from the crash bracket.
19. Remove the crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
20. Remove the stud.
21. Disconnect the fuel pressure and temperature sensor electrical connector and the vacuum hose.
22. Remove the generator harness position retainer from the LH front shed.
23. Remove the fuel charging wiring pin-type retainer from the rear of the manifold.
24. Disconnect the ground wire connector from the RH rear stud.
25. Disconnect the coolant temperature sensor electrical connector.
26. Remove the bolts and the eight ignition coils.
27. Remove the bolts and the coolant outlet adapter.
28. Remove the thermostat and discard the O-ring.
29. Remove the bolts and the intake manifold.
30. Remove and discard the intake manifold gaskets.
31. Clean the sealing surfaces.
Installation
1. NOTE: Align the gasket locator tabs with the slots in the cylinder head.
Install new intake manifold gaskets.
2. Install the intake manifold and hand-tighten the bolts at the locations shown.
3. Install the ignition coils and tighten the bolts.
4. Install the crash bracket and loosely install the bolt and the shed.
5. Tighten the bolts in the sequence shown.
6. Tighten the stud.
7. Connect the EGR system module tube to the EGR system module.
8. Install the EGR Tube nut at the exhaust manifold.
9. Position the EGR system module tube heat shield and install the bolts.
10. Connect the throttle control and the TP sensor electrical connectors.
11. Install the thermostat and O-ring.
12. Install the thermostat housing and the bolts
13. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.
Install the upper radiator hose.
14. Install the generator mounting bracket and the bolts.
15. Connect the electrical connector.
16. Position the vacuum harness and connect the vacuum hoses to the EVAP canister purge valve.
17. Connect the electrical connector and the vacuum hoses.
18. Connect the fuel pressure and temperature sensor electrical connector and the vacuum hose.
19. Connect the fuel charging wiring electrical connectors to the eight fuel injectors.
20. Connect the fuel charging wiring electrical connectors to the eight ignition coils.
21. Install the fuel charging wiring pin-type retainer to the rear of the manifold.
22. Install the generator harness position retainer to the LH front stud.
23. Attach the fuel charging wiring pin-type retainer to the crash bracket.
24. Connect the ground wire connector to the RH rear stud.
25. Connect the coolant temperature sensor electrical connector.
26. Install the wiper mounting arm and pivot shaft.
27. Connect the fuel spring lock coupling.
28. Install the air cleaner and outlet pipe.
29. Connect the battery ground cable.
30. Fill and bleed the engine cooling system.