Intake Manifold: Service and Repair
Intake Manifold Removal1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant.
5. Remove the engine beautification cover retaining nut and engine beautification cover.
6. Remove the air filter snorkel.
7. Remove the VIS vacuum tank.
8. Disconnect the fuel pressure regulator vacuum hose.
9. Disconnect the fuel line.
10. Remove the breather hose.
11. Remove the PCV vacuum hose.
12. Remove the air filter outlet hose.
13. Remove the throttle body assembly.
14. Disconnect the charcoal canister purge solenoid connector and hose.
15. Disconnect the Oxygen Sensor (O2S) connector.
16. Disconnect the Manifold Absolute Pressure (MAP) sensor connector
17. Disconnect the Crankshaft Position (CKP) sensor connector.
18. Disconnect the Exhaust Gas Recirculation (EGR) solenoid connector.
19. Disconnect the Camshaft Position (CMP) sensor connector.
20. Remove the Intake Air Temperature (IAT) sensor.
21. Disconnect the ignition coil connector.
22. Remove the vacuum hose on the brake booster.
23. Remove the EGR pipe from the intake manifold.
24. Remove the engine coolant temperature sensor.
25. Remove the Mining harness from the support bracket on the cylinder block.
26. Remove the intake manifold retaining nuts/bolts and the intake manifold.
27. Remove the bolts on the intake manifold support bracket.
28. Remove the intake manifold gaskets.
29. Clean the contact surfaces between intake manifold and the cylinder head.
NOTE: Remove the fuel rail after removing the intake manifold.
Intake Manifold Installation
1. Installation should follow the removal procedure in the reverse order.
2. Discard used intake manifold gaskets and install new ones.
3. Tighten the intake manifold retaining nuts and bolts.
NOTE: Install the intake manifold after installing the fuel rail.
CAUTION: Genuine intake manifold retaining bolts within the specifications should be used to prevent damaged intake manifold from impairing the airflow to the cylinder.
Tighten the seven (7) intake manifold retaining bolts to 10 - 14 Nm (89 - 124 inch lbs.).
Tighten the four (4) intake manifold retaining nuts to 10 - 14 Nm (89 - 124 inch lbs.).
Tighten the two (2) bolts on the intake manifold support bracket to 10 - 14 Nm (89 - 124 inch lbs.).
4. Tighten the intake EGR pipe retaining bolts on the intake manifold. Refer to Intake EGR Pipe Installation.
Tighten the intake EGR pipe retaining bolts to 8 - 12 Nm (71 - 106 inch lbs.).
5. Install the Intake Air Temperature (IAT) sensor.
Tighten the IAT sensor to 20 - 30 Nm (15 - 22 ft. lbs.).
6. Install the throttle body assembly.
Tighten the throttle body assembly retaining bolts to 8 - 18 Nm (6 - 13 ft. lbs.).
7. Install the fuel pressure regulator.
Tighten the fuel pressure regulator retaining bolts to 10 - 13 Nm (89 - 115 inch lbs.).
8. Install the VIS vacuum tank.
Tighten the VIS vacuum tank retaining bolts to 7 - 9 Nm (62 - 80 inch lbs.).
9. Install the air filter snorkel.
Tighten the air filter snorkel retaining bolts to 5 - 7 Nm (44 - 62 inch lbs.).
10. Install the engine beautification cover.
Tighten the engine beautification retaining bolts to 8 - 12 Nm (71 - 106 inch lbs.).