Intake Manifold Replacement (LUK)

Intake Manifold Replacement (LUK)

Removal Procedure





1. Remove the air cleaner outlet duct (2). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.





2. Remove the intake manifold cover (2). Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement





3. Reposition the hose clamp (1) and disconnect the radiator inlet hose (2). Refer to Radiator Inlet Hose Replacement (LUK) Radiator Inlet Hose Replacement (LUK)Radiator Inlet Hose Replacement (LHU) Radiator Inlet Hose Replacement (LHU)Radiator Inlet Hose Replacement (LEA) Radiator Inlet Hose Replacement (LEA).





4. Remove the starter generator. Refer to Starter Generator Replacement Starter Generator Replacement





5. Disconnect the fuel injector wiring harness electrical connector (3) from the engine wiring harness electrical connector.

6. Remove the fuel injector wiring harness fastener (4) from the intake manifold.

7. Disconnect the evaporative emission (EVAP) canister purge tube (1) from the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.

8. Disconnect the MAP sensor connector (2).





9. Disconnect the fuel pump electrical connector (1).

10. Disconnect the engine wiring harness electrical connector (2) from the throttle actuator control (TAC).

11. Reposition the vacuum brake booster hose clamp (3) at the intake manifold.

12. Remove the vacuum brake booster hose (4) from the intake manifold.

13. Reposition the engine harness (5) away from the intake manifold.





14. Remove the throttle body (2). Refer to Throttle Body Assembly Replacement Removal and Replacement.

15. Remove the fastener (3) from the oil level indicator tube and remove the tube. Refer to Oil Level Indicator Tube Replacement Service and Repair.





16. Remove the fuel feed pipe (2). Refer to Fuel Feed Pipe Replacement Fuel Feed Pipe Replacement.





17. Remove the fuel pump cover (1-4). Refer to Fuel Pump Cover Replacement Fuel Pump Cover Replacement.





18. Remove the intake manifold heat shield (1).





19. Remove the intake manifold lower bolts (1).

20. Remove the intake manifold upper nuts (2).

21. Remove the intake manifold (3).

Note:
The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

22. Remove and inspect the intake manifold gasket.

Installation Procedure





1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.

2. Install the intake manifold (3).

3. Install the intake manifold upper nuts (2).

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install the intake manifold lower bolts (1). Tighten the bolts/nuts (1 and 2) to 10 Nm (89 lb in).





5. Install the intake manifold heat shield (1).





6. Install the fuel pump cover (1-4). Refer to Fuel Pump Cover Replacement Fuel Pump Cover Replacement.





7. Install the fuel feed pipe (2). Refer to Fuel Feed Pipe Replacement Fuel Feed Pipe Replacement.





8. Install the throttle body (2). Refer to Throttle Body Assembly Replacement Removal and Replacement.

9. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement Service and Repair.





10. Reposition the engine harness (5) across the intake manifold.

11. Connect the engine wiring harness electrical connector (2) to the throttle actuator control (TAC).

12. Connect the vacuum brake booster hose (4) at the intake manifold.

13. Install the brake booster hose clamp (3).

14. Connect the fuel pump electrical connector (1).





15. Connect the fuel injector wiring harness electrical connector (3) to the engine wiring harness electrical connector.

16. Install the fuel injector wiring harness fastener (4) to the intake manifold.

17. Connect the evaporative emission (EVAP) canister purge tube (1) to the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.

18. Connect the MAP sensor connector (2).





19. Install the starter generator. Refer to Starter Generator Replacement Starter Generator Replacement





20. Connect the radiator inlet hose (2), reposition the hose clamp (1). Refer to Radiator Inlet Hose Replacement (LUK) Radiator Inlet Hose Replacement (LUK)Radiator Inlet Hose Replacement (LHU) Radiator Inlet Hose Replacement (LHU)Radiator Inlet Hose Replacement (LEA) Radiator Inlet Hose Replacement (LEA).





21. Install the intake manifold cover (2). Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement





22. Install the air cleaner outlet duct (2). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.