Intake Manifold: Service and Repair

Removal
1. Relieve fuel pressure.
2. Disconnect negative cable at battery.





3. Drain coolant.

WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.

4. Remove air cleaner outlet hose.





5. Disconnect the following electric lead wires:
^ EGR valve coupler
^ IAC valve coupler
^ TP sensor coupler
^ EVAP canister purge valve coupler
^ Ground terminal from intake manifold
^ MAP sensor
6. Disconnect accelerator cable and A/T throttle cable (For A/T vehicle) from throttle body.





7. Disconnect the following hoses:
^ Brake booster hose from intake manifold
^ PCV hose from intake manifold
^ Fuel pressure regulator vacuum hose from intake manifold
^ Canister purge hose from EVAP canister purge valve
^ Vacuum hose from intake manifold
^ Water hoses from throttle body and water bypass pipe
^ Breather hose from throttle body
^ Fuel feed hose and return hose from each pipe
8. Remove fuel delivery pipe with fuel injectors from cylinder head.
9. Remove intake manifold front stiffener and rear stiffener.
10. Detach water pipe from intake manifold.





11. Remove intake manifold (1) from cylinder head, and then its gasket (2).

Installation
Reverse removal procedure for installation noting the followings.





^ Use new intake manifold gasket (1).
^ Install fuel delivery pipe with fuel injectors to cylinder head.





^ Adjust accelerator cable (1) play and A/T throttle cable (2) play (for vehicle with A/T).
^ Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
^ Refill cooling system.
^ Upon completion of installation, turn ignition switch ON but engine OFF and check for fuel leaks.
^ Finally, start engine and check for engine coolant leaks.