Intake Manifold: Service and Repair
Intake Manifold Assembly
Service Repair No - 30.15.02
Special Tools
Special Tools:
Removal
1. Secure the hood in the service position.
^ Release the support struts.
2. Disconnect the battery ground cable.
3. Remove the throttle body gasket.
4. Remove the engine cover brackets.
^ Release the electrical connectors from the engine cover brackets.
^ Remove the 4 nuts.
CAUTION: Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.
5. Disconnect the crankcase vent hoses.
6. Disconnect the evaporative emission hose from the intake manifold assembly.
7. Release the evaporative loss control valve from the intake manifold mounting, move the hose assembly aside for access.
8. Release the fuel pipe from the clips.
9. Using the special tool, disconnect the fuel line.
^ Position an absorbent cloth to collect fluid spillage.
10. Release the camshaft position (CMP) sensor connector block from the intake manifold assembly.
11. Position the wiring harness support bracket aside for access.
^ Remove the 2 bolts.
12. Release the EGR valve.
^ Remove the 2 bolts.
^ Discard the gasket.
13. Release the engine wiring harness clips from the fuel rail.
14. Disconnect the fuel injector electrical connectors.
15. Disconnect the fuel temperature sensor electrical connector.
16. Remove the 10 intake manifold bolts.
17. Remove the intake manifold.
^ Disconnect the mass air flow (MAF) sensor electrical connector.
^ Disconnect the brake booster vacuum hose from the intake manifold.
^ Discard the gaskets.
NOTE: Do not disassemble further if the component is removed for access only.
18. Remove the NVH pad from the RH side of the intake manifold.
19. Remove the intake manifold casting.
^ Disconnect the vacuum hose from the intake manifold.
^ Remove the 4 bolts.
20. Remove the intake manifold MAP sensor housing.
^ Remove the 7 bolts.
21. Remove the fuel rail.
^ Remove the 4 Torx bolts.
^ Release the fuel injectors.
^ Discard the fuel injector O-ring seals.
22. Remove the fuel injector housings.
^ Remove the 10 Torx screws.
^ Release the fuel injector housings and discard the gaskets.
Installation
1. Install the fuel injector housings.
^ Clean the component mating faces.
^ Install the gaskets.
^ Install the Torx screws.
2. Install the fuel rail.
^ Clean the component mating faces.
^ Install fuel injector O-ring seals.
^ Lubricate the O-ring seals with clean engine oil.
^ Tighten the 4 Torx bolts to 10 Nm (7 ft. lbs.).
3. Install the intake manifold MAP sensor housing.
^ Clean the component mating faces.
^ Tighten the 7 bolts to 10 Nm (7 ft. lbs.).
4. Install the intake manifold casting.
^ Clean the component mating faces.
^ Install the 4 bolts and tighten to 10 Nm (7 ft. lbs.).
5. Install the NVH pad to the RH side of the intake manifold.
6. Clean the components.
7. With assistance, install the intake manifold.
^ Install the gaskets.
^ Connect the mass air flow (MAF) sensor electrical connector.
^ Connect the brake booster vacuum hose to the intake manifold.
8. Install the bolts.
^ Evenly and progressively tighten the bolts to 20 Nm (15 ft. lbs.).
9. Connect the fuel temperature sensor electrical connector.
10. Connect the fuel injector electrical connectors.
11. Connect the engine wiring harness to the intake manifold.
12. Install the EGR valve.
^ Install a new gasket.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
13. Install the engine wiring harness support bracket.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
14. Position the CMP sensor electrical connector block, to the intake manifold.
15. Connect the fuel line to the fuel rail.
^ Clean the component mating faces.
^ Position the fuel pipe into clips.
16. Install the evaporative loss valve assembly to the intake manifold bracket and connect the hose.
^ Clean the component mating faces.
17. Connect the crankcase vent hoses.
^ Clean the component mating faces.
18. Install the engine cover mounting brackets.
^ Tighten the nuts to 6 Nm (4 ft. lbs.).
^ Attach the wiring harness connector blocks to the brackets.
19. Install the throttle body gasket.
20. Connect the battery ground cable.
21. Connect the hood support struts.