Intake Manifold: Service and Repair

REMOVAL PROCEDURE

^ Tools Required
- J 37088-A Fuel Line Quick Connect Separator Tool Set

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.





2. Remove the four intake manifold sight shield nuts.
3. Remove the intake manifold sight shield.
4. Relieve the fuel system pressure.
5. Remove the air cleaner outlet duct from the throttle body.
6. Remove the TP sensor and the IAC valve connectors.
7. Disconnect the accelerator cable and the cruise control cable at the throttle body.
8. Disconnect the front bank spark plug wires and lay aside.
9. Drain the cooling system.





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 J 37088-A 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 left rear engine bracket.
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.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the four intake manifold studs.

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.
^ Tighten the bolts and studs to 10 Nm (89 inch lbs.).

4. Install the injector harness main connector.
5. Install the PCV hose at the intake manifold.
6. Connect the fuel rail bracket at the left rear engine bracket.
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 25 Nm (18 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 shift cable at the bracket. Install the air cleaner outlet 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.





21. Install the four intake manifold sight shield nuts.
^ Tighten the four intake manifold sight shield nuts to 3 Nm (27 inch lbs.).
22. Fill the cooling system.