Intake Manifold: Service and Repair
REMOVAL PROCEDURE^ Tools Required
- J 37088 Fuel Line Quick Connect Separator Tool Set
1. Disconnect the negative battery cable.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
2. Remove the four intake manifold sight shield nuts.
3. Remove the intake manifold sight shield. Refer to Engine Cover Replacement Service and Repair
4. Relieve the fuel system pressure. Refer to Fuel Pressure Release in Powertrain Management.
5. Remove the air intake duct from the throttle body.
6. Remove the transaxle vent hose and the transaxle shift cable at the bracket.
7. Remove the TP sensor and the IAC valve connectors.
8. Disconnect the accelerator cable and the cruise control cable at the throttle body.
9. Disconnect the front bank spark plug wires and lay aside.
10. Disconnect the throttle body coolant hoses at the throttle body and surge tank pipe.
11. Disconnect the EGR pipe and crankcase ventilation pipe at the throttle body spacer.
12. Disconnect the brake booster vacuum hose at the intake manifold vacuum fitting.
13. Disconnect the fuel rail ground wire at the rear cylinder head.
14. Remove the quick-connect fittings at the fuel rail using the following procedure:
14.1. Grasp both sides of the fitting.
14.2. Twist the female connector 1/4 turn in each direction in order to loosen any dirt within the fitting.
CAUTION: Wear safety glasses when using compressed air in order to prevent eye Injury.
14.3. Using compressed air, blow the dirt out of the fitting.
14.4. Choose the correct tool from the J37088 for the size of the fitting.
14.5. Insert the tool into the female connector, then push/pull inward to release the locking tabs.
14.6. Pull the connection apart.
14.7. Using a clean shop towel, wipe off the male pipe end.
14.8. Inspect both ends of the fitting for dirt and burrs.
14.9. Clean or replace the components as required.
15. Disconnect the fuel rail bracket at the EGR valve.
16. Disconnect the PCV hose at the intake manifold.
17. Disconnect the injector harness main connector.
18. Remove the six intake manifold bolts and the four intake manifold studs.
19. Remove the intake manifold.
20. Inspect the intake manifold carrier gaskets. The carrier gaskets are attached to the intake manifold through a snap-lock feature. When removing the intake manifold, the carrier gaskets will remain attached to the manifold.
INSTALLATION PROCEDURE
1. Install the intake manifold.
2. Install the six intake manifold bolts.
3. Install the four intake manifold studs.
^ Tighten the bolts and studs to 10 Nm (89 inch lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
IMPORTANT: Only tighten the intake manifold bolts when the engine and manifold are cool. Do not tighten the intake manifold bolts and studs with the engine at operating temperature.
When tightening the intake manifold bolts and studs, start at the center of the manifold and work your way outward in a circular pattern.
4. Install the injector harness main connector.
5. Install the PCV hose at the intake manifold.
6. Connect the fuel rail bracket at the EGR valve.
7. Connect the quick connect fittings to the fuel rail using the following procedure:
7.1. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet tubes.
7.2. Push both sides of the fitting together in order to cause the retaining tabs to snap into place.
7.3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
8. Connect the fuel rail ground wire at the rear cylinder head.
9. Connect the brake booster vacuum hose at the intake manifold vacuum fitting.
10. Install the EGR pipe and crankcase ventilation pipe at the throttle body spacer.
^ Tighten the EGR pipe bolt to 28 Nm (21 ft. lbs.).
11. Connect the throttle body coolant hoses at the throttle body and surge tank pipe.
12. Connect the front bank spark plug wires.
13. Connect the accelerator cable and cruise control cable at the throttle body.
14. Install the TP sensor and the IAC valve connectors.
15. Install the transaxle vent hose and transaxle shift cable at the bracket. Install the air intake duct.
16. Install the fuel filler cap.
17. Connect the negative battery cable.
18. Turn the ignition switch to the ON position for two seconds, then turn the OFF position for ten seconds.
19. Again turn to the ON position. Check for fuel leaks.
20. Install the intake manifold sight shield. Refer to Engine Cover Replacement Service and Repair
21. Install the four intake manifold sight shield nuts.
^ Tighten the nuts to 3 Nm (27 inch lbs.).