Intake Manifold Replacement (LEA)

Intake Manifold Replacement (LEA)

Removal Procedure

1. Recover the A/C system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.

3. Remove the air cleaner outlet duct. Refer to Air Cleaner Assembly Replacement Service and Repair.





Caution:
Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold can be damaged if it is removed when the engine is hot.

4. Remove the intake manifold cover (1). Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement





5. Remove the evaporative (EVAP) emission canister valve tube (1) from the intake manifold and reposition.

6. Remove the MAP sensor (3) electrical connector.





7. Remove the throttle body (1). Refer to Throttle Body Assembly Replacement Removal and Replacement.





8. Remove the fuel pump cover (3) and insulator (2). Refer to Fuel Pump Cover Replacement Fuel Pump Cover Replacement.

Note:
The low pressure fuel pipe used is model dependent.

9. Disconnect and reposition the low pressure fuel feed pipe from the fuel pump. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.





10. Remove the fuel rail harness connector bracket bolt (1) and intake manifold insulator bolt.

11. Remove the intake manifold insulator (2).





12. Remove the A/C line nut (1) and line (2) from the compressor and reposition the line to the side.





Note:
Removing studs allows the intake manifold to be removed without removing the fuel pump.

13. Remove the intake manifold retaining nuts (1), studs (3), and bolts (2).

14. Remove the intake manifold (1).

15. Disconnect electrical connectors as necessary.

16. Transfer parts as necessary.

17. If reusing the intake manifold, clean and inspect as necessary. Refer to Intake Manifold Cleaning and Inspection (LAF, LEA, or LUK) 39. Intake Manifold Cleaning and Inspection.

Installation Procedure





1. Position the intake manifold (4) and hand start the bolts (2).

Caution:
Refer to Fastener Caution Fastener Caution.

2. Install the intake manifold studs (3) and tighten to 6 Nm (53 lb in).





3. Tighten the bolts (2) and nuts (1) in sequence to 10 Nm (89 lb in).





4. Install the intake manifold insulator (2).

5. Install the insulator bolt and tighten to 10 Nm (89 lb in).

6. Install the fuel rail harness connector bracket (1) to the intake manifold. Tighten the bracket bolt to 10 Nm (89 lb in).





7. Install new seal washers to the compressor hose. Refer to Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement.

8. Install the compressor hose (2) to the compressor.

9. Install the compressor hose nut (1) to the compressor and tighten the nut to 22 Nm (16 lb ft).

10. Connect the engine harness electrical connector as necessary.





11. Install the fuel pump insulator (2) and cover (3). Refer to Fuel Pump Cover Replacement Fuel Pump Cover Replacement.

Note:
The low pressure fuel pipe used is model dependent.

12. Install the low pressure fuel pipe assembly (1).





13. Install a new throttle body gasket.

14. Install the throttle body (1). Refer to Throttle Body Assembly Replacement Removal and Replacement.





15. Install the EVAP canister valve tube (1).

16. Connect the MAP sensor electrical connector.





Caution:
Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold can be damaged if it is removed when the engine is hot.

17. Install the intake manifold cover (1). Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement

18. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.