Intake Manifold: Service and Repair
Intake ManifoldService Repair No - 30.15.02
Special Service Tools
Removal
CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean and dry. Plug open connections to prevent contamination.
1. Disconnect the battery ground cable.
2. Remove the plenum chamber.
3. Remove the purge valve assembly.
4. Release the throttle body.
5. Disconnect the throttle body electrical connector.
^ Position the throttle body aside for access.
6. Disconnect the crankcase vent hose.
^ Position aside.
7. Disconnect the 2 heater coolant hoses.
^ Release the 2 clips.
^ Clamp the relevant hose, to minimize coolant loss.
^ Position an absorbent cloth to collect fluid spillage.
8. Release the heater hose support bracket.
^ Remove the 3 nuts.
^ Tie the bracket aside.
9. Remove the LH engine cover bracket.
^ Release the electrical connector.
10. Remove the RH engine cover bracket.
^ Remove the 2 nuts.
^ Remove the bolt.
^ Release the electrical connector.
11. Release the EGR valve.
^ Remove the 2 bolts.
^ Discard the gasket.
12. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
13. Disconnect the brake booster vacuum hose from the intake manifold.
14. Disconnect the fuel temperature sensor electrical connector.
15. Release the wiring harness bridge.
^ Remove the 2 bolts.
16. Release the engine wiring harness clips.
^ Release the 4 clips.
17. Disconnect the fuel injector electrical connectors.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
18. Using the special tool, disconnect the fuel line.
^ Remove the clip.
19. Remove the intake manifold assembly.
^ Remove the 10 bolts.
^ Discard the 2 gaskets.
NOTE: Do not disassemble further if the component is removed for access only.
20. Remove the intake manifold casting.
^ Disconnect the vacuum hose from the intake manifold.
^ Remove the 4 bolts.
21. Remove the NVH pad from the RH side of the intake manifold.
22. Remove the intake manifold MAP sensor housing.
^ Remove the 7 bolts.
23. Remove the fuel rail.
^ Remove the 4 Torx bolts.
^ Release the fuel injectors.
^ Remove and discard the fuel injector O-ring seals.
24. 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. Install the intake manifold assembly.
^ Install the gaskets.
7. Install the bolts.
^ Evenly and progressively tighten the bolts to 20 Nm (15 ft. lbs.).
8. Connect the MAP sensor electrical connector.
9. Connect the fuel temperature sensor electrical connector.
10. Connect the brake booster vacuum hose.
11. Connect the fuel injector electrical connectors.
12. Secure the engine wiring harness.
^ Position and secure the clips.
^ Install the bolts and tighten to 10 Nm (7 ft. lbs.).
13. Install the EGR valve.
^ Install a new gasket.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
WARNING: After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may result in personal injury.
14. Connect the fuel line to the fuel rail.
^ Clean the component mating faces.
^ Position the fuel pipe into clips.
15. Install the engine cover mounting brackets.
^ Tighten the nuts to 6 Nm (4 ft. lbs.).
^ Attach the wiring harness connector blocks to the brackets.
16. Install the heater hose support bracket.
^ Tighten the nuts to 10 Nm (7 ft. lbs.).
17. Connect the heater coolant hoses.
^ Remove the hose clamps.
18. Connect the crankcase vent hoses.
^ Clean the component mating faces.
19. Install the throttle body.
20. Connect the throttle body electrical connector.
21. Install the purge valve.
22. Install the plenum chamber.
23. Connect the battery ground cable.
24. Check and top-up the coolant if required.