Intake Manifold: Service and Repair

Intake Manifold (30.15.02)

Removal

1. Disconnect the battery ground cable.
2. Remove the engine cover.
3. Remove the air cleaner assembly.

4. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

5. Remove the engine undershield.

6.





7.





8. Remove the air cleaner outlet pipe.





9. Remove the 2 lower intake manifold bolts.





10. Disconnect the MAP sensor electrical connector.





11. Disconnect the throttle body electrical connector.





12. Disconnect the fuel purge line.
13. Disconnect the purge control valve (PCV) electrical connector.





14. Disconnect the fuel rail pressure (FRP) sensor electrical connector.
15. Remove the dipstick.

16. CAUTION: Be prepared to collect escaping fluids.

Disconnect the coolant bleed hose.





17. Release the PAS fluid reservoir from the bracket and tie aside.





18. Remove the A/C line support bracket.





19. Remove the cooling fan module.





20. Remove the intake manifold.





21. Disconnect the 2 intake manifold module connectors.





22. NOTE: Do not disassemble further if the component is removed for access only.

Remove the throttle body.





23. Remove the 2 intake manifold modules.





24. Remove the purge valve assembly.





25. Remove the manifold absolute pressure (MAP) sensor.





26. Remove and discard the intake manifold gaskets.





Installation

1. Clean the component mating faces.
2. Install the gaskets.
3. Install the intake manifold modules.
4. Install the MAP sensor.
5. Install the purge valve assembly.
6. Install the throttle body and tighten the screws in the sequence shown.

Torque:
8 Nm





7. Install the inlet manifold and tighten the bolts.

Torque:
16 Nm

8. Install the cooling fan module.
9. Connect the coolant bleed hose.
10. Install the PAS fluid reservoir in the bracket.
11. Install the dipstick.
12. Connect and secure the electrical connectors.
13. Install the A/C line support bracket and tighten the bolt.

Torque:
10 Nm

14. Connect the purge line.
15. Install the lower intake manifold bolts.

Torque:
10 Nm

16. Install the air cleaner outlet pipe.
17. Install the engine undershield.
18. Install the front undershield.
19. Install the front towing eye cover.
20. Install the air cleaner assembly.
21. Install the engine cover.
22. Connect the battery ground cable.
23. Check and top-up the coolant.