Intake Manifold: Service and Repair

Intake Manifold

Intake Manifold (View 1 of 2)









Intake Manifold (View 2 of 2)









Removal and Installation

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. NOTICE: Before removing the high voltage cables, the vehicle electrical system must be completely shut down for at least 5 minutes to allow for the high voltage capacitors to discharge.

Depower the vehicle high voltage electrical system. For additional information, refer to High Voltage Traction Battery High-Voltage Traction Battery Systems Depowering.

3. Remove the fuel rail. For additional information, refer to Fuel Charging and Controls - Hybrid Fuel Rail.

4. Remove the Throttle Body (TB). For additional information, refer to Fuel Charging and Controls - Hybrid Service and Repair.

5. Remove the accessory drive belt tensioner. For additional information, refer to Accessory Drive - Hybrid Accessory Drive Belt Tensioner.

6. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.

7. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.

8. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.

9. Disconnect the EVAP tube-to- EVAP canister purge valve quick connect coupling and the vacuum tube from the intake manifold.

10. Detach the 3 wiring retainers from the intake manifold near the throttle body mounting area.

11. Disconnect the auxiliary coolant pump electrical connector and detach the 2 wiring retainers.

12. Detach the lower radiator hose retainer from the intake manifold.

13. Detach the engine wiring harness retainer and the vehicle high voltage electrical system wire retainer from the intake manifold.

14. Disconnect the Knock Sensor (KS) electrical connector and detach the retainer from the intake manifold.

15. Remove the cooling fan motor and shroud. For additional information, refer to Engine Cooling - Hybrid Service and Repair.

16. Remove the 3 A/C compressor bolts and position the compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).

17. NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts.

Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector.

- To install, tighten to 18 Nm (159 lb-in).





18. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.





19. Remove the intake manifold and gaskets.

20. 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.

To install, reverse the removal procedure.

- Inspect and install new intake manifold gaskets if necessary.