Intake Manifold Replacement

Intake Manifold Replacement

Removal Procedure





Important: The intake manifold, throttle body, fuel injection rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

1. Remove the engine sight shield.
2. Remove the air cleaner outlet duct.
3. Disconnect the fuel injector electrical connectors.
4. Disconnect the throttle body electrical connector.
5. Relieve the fuel system pressure.
6. Remove the engine compartment fuel feed pipe.
7. Remove the fuel rail if necessary.
8. Remove the vacuum hose from the intake manifold. Position the hose aside.




9. Disconnect the electrical connector from the manifold absolute pressure (MAP) sensor.
10. Remove the MAP sensor (714).
11. Remove the grommet (715) from the sensor, as required.




12. Remove the evaporative emission (EVAP) clip (740), bolt (742), bracket (741), valve (730), and tubes (729, 735).




13. Remove the intake manifold bolts (512) and fuel rail stop bracket (712).
14. Remove the intake manifold (500).




15. Remove and discard the intake manifold gaskets (514).
16. Disassemble the intake manifold as necessary. Refer to the appropriate procedures.
17. Clean and inspect the intake manifold if it is not being replaced.

Installation Procedure





Important: DO NOT reuse the intake manifold gaskets. Install NEW intake manifold gaskets.

Important:
* The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, install the intake manifold as a complete assembly.

* DO NOT use the intake manifold gaskets again. Install NEW intake manifold-to-cylinder head gaskets.

Install NEW intake manifold-to-cylinder head gaskets (514).




1. Install the intake manifold (500).
2. Apply a 5 mm (0.20 in) band of threadlocker to the threads of the intake manifold bolts (512). Refer to Sealers, Adhesives, and Lubricants for the correct part number.





Notice: Refer to Fastener Notice.

3. Install the fuel rail stop bracket (712).
4. Install the intake manifold bolts (512).

* First Pass: Tighten the intake manifold bolts in sequence to 5 N.m (44 lb in).
* Final Pass: Tighten the intake manifold bolts in sequence to 10 N.m (89 lb in).




5. Lubricate the MAP sensor grommet (715) with clean engine oil.
6. Install the MAP sensor (714) and grommet (715).




7. Install the EVAP valve (730), bracket (741), and bolt (742).

Tighten the bolt to 50 N.m (37 lb ft).

8. Install the EVAP tubes (729, 735).
9. If previously removed, install the fuel rail.
10. Connect the MAP sensor electrical connector.




11. Install the brake booster vacuum hose to the intake manifold.
12. Connect the throttle body electrical connector.
13. Connect the fuel injector electrical connectors.
14. Install the air cleaner outlet duct.
15. Install the engine sight shield.