Intake Manifold: Service and Repair

REMOVAL
1. Disconnect negative cable at battery.





2. 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.





3. Disconnect IAT sensor wire at coupler.
4. Remove air cleaner outlet hose.





5. Disconnect accelerator cable from throttle body.
6. Remove accelerator cable from bracket.





7. Disconnect the following electric lead wires:
^ IAC valve coupler
^ TP sensor coupler
^ MAF sensor coupler
^ EGR valve coupler
^ EVAP canister purge valve coupler
^ MDP sensor coupler
^ Ground terminal from throttle body





8. Disconnect the following hoses:
^ Brake booster hose from intake manifold
^ PCV hose from PCV valve
^ Fuel pressure regulator vacuum hose from intake manifold
^ Coolant hoses from throttle body and cylinder head
^ Breather hose from throttle body
^ Vacuum hose from EVAP canister purge valve





9. Remove throttle body from intake manifold.





10. Remove intake manifold front stiffener and rear stiffener.





11. Remove EGR pipe.





12. Disconnect coolant pipe from intake manifold.





13. Remove intake manifold from cylinder head, and then its gasket.

INSTALLATION





1. Install new intake manifold gasket to cylinder head.
2. Install intake manifold.
Tighten bolts and nuts to specified torque.
Tightening Torque (a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)





3. Connect coolant pipe to intake manifold.





4. Install EGR pipe.





5. Install intake manifold front stiffener and rear stiffener.
Tighten bolts to specified torque.
Tightening Torque
(a): 25 Nm (2.5 kg-m, 18.0 ft. lbs.)
(b): 50 Nm (5.0 kg-m, 36.5 ft. lbs.)





6. Install throttle body to intake manifold with new gasket.
Tighten bolts and nuts to specified torque.





7. Connect the following hoses:
^ Brake booster hose to intake manifold
^ PCV hose to PCV valve
^ Fuel pressure regulator vacuum hose to intake manifold
^ Coolant hoses to throttle body and cylinder head
^ Breather hose to throttle body
^ Vacuum hose to EVAP canister purge valve





8. Connect the following electric lead wires:
^ IAC valve
^ TP sensor
^ MAF sensor
^ EGR valve
^ EVAP valve canister purge valve
^ MDP sensor
^ Grand terminal from throttle body





9. Install accelerator cable to bracket.
10. Connect accelerator cable to throttle body.
Adjust accelerator cable play.
11. Install air cleaner outlet hose.
12. Connect IAT sensor wire at coupler.
13. Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
14. Refill cooling system.
15. Connect negative cable at battery.
16. Finally, start engine and check for engine coolant leaks.