Intake Manifold: Service and Repair

Intake Manifold

Intake Manifold (View 1 of 2)










Intake Manifold (View 2 of 2)









Removal

NOTICE: 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. Remove the Air Cleaner (ACL) outlet pipe.

2. Disconnect the radio capacitor electrical connector.

3. Disconnect the RH spark plug wires from the ignition coil.

4. Detach the RH spark plug wire retainer from the intake manifold.

5. Remove the 2 ignition coil bracket upper bolts.

6. Remove the 2 ignition coil lower bolts.
- Position the ignition coil and bracket assembly aside.

7. Disconnect the EGR system module electrical connector.

8. Disconnect the EGR system module tube from the EGR system module.

9. Disconnect the brake booster vacuum hose from the intake manifold.

10. Disconnect the vacuum tube from the fuel rail pressure and temperature sensor.

11. Disconnect the vapor tube from the intake manifold.

12. Remove the PCV tube.

13. Detach the Knock Sensor (KS) electrical connector retainer from the intake manifold.

14. Disconnect the Throttle Position (TP) sensor and Throttle Body (TB) electrical connectors.

15. Remove the 8 bolts and the intake manifold.

Installation

1. 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.

NOTE: Clean and inspect all sealing surfaces. Inspect and install new gaskets as necessary.

Position the intake manifold and install the 8 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





2. Connect the TP sensor and TB electrical connectors.

3. Attach the KS electrical connector retainer to the intake manifold.

4. Install the PCV tube.

5. Connect the vapor tube to the intake manifold.

6. Connect the vacuum tube to the fuel rail pressure and temperature sensor.

7. Connect the brake booster vacuum hose to the intake manifold.

8. Connect the EGR system module tube to the EGR system module.
- Tighten to 40 Nm (30 lb-ft).

9. Connect the EGR system module electrical connector.

10. Position the ignition coil and bracket assembly. Install the 2 lower bolts.
- Tighten the M8 bolt to 24 Nm (18 lb-ft).

- Tighten the M12 bolt to 34 Nm (25 lb-ft).

11. Install the 2 ignition coil bracket upper bolts.
- Tighten to 9 Nm (80 lb-in).

12. Attach the RH spark plug wire retainer to the intake manifold.

13. Connect the RH spark plug wires to the ignition coil.

14. Connect the radio capacitor electrical connector.

15. Install the ACL outlet pipe.