Intake Manifold: Service and Repair
Intake Manifold Removal and InstallationIntake Manifold 2004-2005 Models:
Intake Manifold 2006 Model:
Removal (2004-2005 models)
1. Disconnect the intake air temperature (IAT) sensor connector (A).
2. Remove the vacuum hose (B) and breather pipe (C), then remove the air intake duct (D).
3. Remove the intake manifold cover.
4. Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (8).
5. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
^ Throttle actuator connector
^ Manifold absolute pressure (MAP) sensor connector
6. Remove the harness holder (A), harness bracket (B), and remove the harness clamp (C).
7. Remove and plug the water bypass hoses.
8. Remove the harness clamp (A) and the harness connector (B) from the intake manifold bracket, then remove the intake manifold bracket (C).
9. Remove the vacuum hose.
10. Remove the intake manifold.
Installation (2004-2005 models)
1. Install the intake manifold (A) with a new gasket (B), and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt.
2. Install the vacuum hose.
3. Install the intake manifold bracket (A), then install the harness clamp (B), and harness connector (C) to the intake manifold bracket.
4. Install the water bypass hoses.
5. Install the harness holder (A), harness bracket (B), and install the harness clamp (C).
6. Reconnect the MAP sensor and throttle actuator connectors.
7. Install the EVAP canister hose (A) and brake booster vacuum hose (B).
8. Install the intake manifold cover.
9. Install the air intake duct (A), then connect the IAT sensor connector (B), and install the vacuum hose (C) and breather pipe (D).
10. Clean up any spilled engine coolant.
11. After installation, check that all tubes, hoses, and connectors are installed correctly.
12. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
Removal (2006 model)
1. Disconnect the intake air temperature (IAT) sensor connector (A).
2. Remove the vacuum hose (B) and breather pipe (C), then remove the air intake duct (D).
3. Remove the intake manifold cover.
4. Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
5. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
^ Throttle actuator connector
^ Manifold absolute pressure (MAP) sensor connector
6. Remove the harness holder (A), harness bracket (B), and remove the harness clamp (C).
7. Remove and plug the water bypass hoses.
8. Remove the harness clamp (A) and the harness connector (B) from the intake manifold bracket, then remove the intake manifold bracket (C).
9. Remove the vacuum hose.
10. Remove the intake manifold.
Installation (2006 model)
1. Install the intake manifold (A) with a new gasket (B), and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt.
2. Install the vacuum hose.
3. Install the intake manifold bracket (A), then install the harness clamp (B), and harness connector (C) to the intake manifold bracket.
4. Install the water bypass hoses.
5. Install the harness holder (A), harness bracket (B),and install the harness clamp (C).
6. Reconnect the MAP sensor and throttle actuator connectors.
7. Install the EVAP canister hose (A) and brake booster vacuum hose (B).
8. Install the intake manifold cover.
9. Install the air intake duct (A), then connect the IAT sensor connector (B), and install the vacuum hose (C) and breather pipe (D).
10. Clean up any spilled engine coolant.
11. After installation, check that all tubes, hoses, and connectors are installed correctly.
12. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.