Intake Manifold: Service and Repair

Removal Procedure





1. Drain the cooling system.
2. Raise and suitably support the vehicle. Refer to Vehicle Lifting
3. Remove the transmission fluid level indicator tube bolt.
4. Lower the vehicle.
5. Relieve the fuel system pressure. Refer to Fuel Pressure Release.

Important: Cap the fittings and plug the holes when separating fuel system components in order to prevent dripping of fuel and/or dirt and other contaminants from entering the fuel system.





6. Disconnect the fuel line from the fuel rail.
7. Disconnect the vapor line from the fuel vapor purge valve.





8. Disconnect the intake air temperature (IAT) sensor electrical connector.
9. Disconnect the mass airflow (MAP) sensor electrical connector.





10. Remove the air intake duct from the throttle body and the air cleaner box.





11. Disconnect the idle air control (IAC) valve electrical connector from the throttle body.
12. Disconnect the throttle position sensor (TPS) electrical connector from the throttle body.
13. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory.





14. Disconnect the exhaust gas recirculation (EGR) solenoid electrical connector.





15. Remove the EGR valve pipe bolts (2, 3, and 4).
16. Using mild force, pull the EGR valve pipe (1) up out of the intake manifold.
17. Remove the O-ring seal from the EGR valve pipe (1).
18. Discard the exhaust manifold gasket (5) and O-ring seal.





19. Unsnap the cruise control cable from the throttle lever, if equipped.
- Push the cruise cable connector forward to unsnap.
- Unsnap the cable from the engine bracket.





20. Remove the accelerator cable from the throttle lever.





21. Remove the accelerator control cable and cruise control servo bracket.





22. Disconnect the right side fuel injector electrical connectors.





23. Disconnect the left side fuel injector electrical connectors.
24. Disconnect the secondary air injection (AIR) solenoid electrical connector.
25. Remove the fuel rail. Refer to Fuel Rail and Injectors Removal.





26. Remove the fresh air tube from the throttle body and rocker cover.





27. Remove the vapor vent tube from the throttle body.





28. Remove the throttle body heater outlet hose from the throttle body.





29. Remove the evaporative emission (EVAP) canister purge tube.





30. Remove the canister purge valve and bracket from the intake manifold.





31. Disconnect the knock sensor harness electrical connector (4).





32. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
33. Disconnect the vacuum hose from the vacuum port on the MAP sensor housing.
34. Disconnect all the remaining electrical connections from the intake manifold.
35. Remove the intake manifold. Refer to Intake Manifold Removal.

Installation Procedure





1. Install the intake manifold. Refer to Intake Manifold Installation.
2. Connect the MAP sensor electrical connector.
3. Connect the vacuum hose to the vacuum port on the MAP sensor housing.





4. Connect the knock sensor harness electrical connector (4).





5. Install the canister purge valve and bracket to the intake manifold.





6. Install the EVAP canister purge tube.





7. Install the throttle body heater outlet hose to the throttle body.





8. Install the vapor vent tube hose to the throttle body.





9. Install the fresh air tube to the throttle body and rocker cover.
10. Install the fuel rail. Refer to Fuel Rail and Injectors Installation.





11. Connect the left side fuel injector electrical connectors.
12. Connect the AIR solenoid electrical connector.





13. Connect the right side fuel injector electrical connectors.
14. Connect all remaining electrical connectors to the intake manifold.

Notice: Refer to Fastener Notice in Service Precautions.





15. Install the accelerator control cable and cruise control servo bracket.
- Tighten the accelerator control cable and cruise control servo bracket nut to 10 Nm (89 inch lbs.).





16. Install the accelerator cable to the throttle lever.





17. Install the cruise control cable to the throttle lever, if equipped.

Important: Do not reuse EGR pipe gaskets or seals during assembly, install NEW gaskets and seals.





18. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe (1).
19. Install the EGR valve pipe (1) into the intake manifold.
20. Finger start the EGR valve pipe (1) to intake manifold bolt (2).
21. Finger start the EGR valve pipe (1) to cylinder head bolts (3).
22. Finger start a NEW EGR valve pipe exhaust manifold gasket (5) and bolts (4).
22.1. Tighten the EGR valve pipe to intake manifold bolt (2) to 10 Nm (89 inch lbs.).
22.2. Tighten the EGR valve pipe to cylinder head bolts (3) to 50 Nm (37 ft. lbs.).
22.3. Tighten the EGR valve pipe to the exhaust manifold bolts (4) to 30 Nm (22 ft. lbs.).





23. Connect the EGR valve electrical connector.
24. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory.





25. Connect the TPS sensor electrical connector to the throttle body.
26. Connect the IAC sensor electrical connector to the throttle body.





27. Install the air intake duct to the throttle body and the air cleaner box.





28. Connect the MAP electrical connector to the intake duct.
29. Connect the IAT sensor electrical connector to the intake duct.





30. Connect the fuel line to the fuel rail.
31. Connect the vapor line to the fuel vapor purge valve.
32. Raise and suitably support the vehicle. Refer to Vehicle Lifting.





33. install the transmission fluid indicator tube bolt.
- Tighten the transmission fluid indicator tube bolt to 50 Nm (37 ft. lbs.).
34. Lower the vehicle.
35. Fill the cooling system.