Intake Manifold: Service and Repair

Intake Manifold Removal and Installation

Reference: Throttle Body and Intake Manifold Components

Removal
1. Disconnect negative cable at battery.




2. Drain cooling system.

WARNING: To help avoid danger of being burned, do not remove drain plug (1) 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. Remove engine cover.
4. Remove air cleaner outlet hose.
5. Disconnect accelerator cable (2) from throttle valve lever (1).
6. Disconnect accelerator cable (2) with cable bracket (3) from intake manifold.
7. Disconnect the following electric lead wires:
- IAC valve coupler (4)
- TP sensor coupler (5)
- EGR valve coupler (6)
- EVAP canister purge valve coupler (7)
- MAP sensor coupler (8)
- Ground terminal (9) from throttle body
8. Disconnect the following hoses:
- Brake booster hose (10) from intake manifold
- PCV hose (11) from PCV valve
- Fuel pressure regulator vacuum hose (12) from intake manifold
- Coolant hoses from (13) throttle
- Breather hose (14) from throttle body
- Vacuum hose (15) from EVAP canister purge valve




9. Remove intake manifold front stiffener (16).




10. Remove rear stiffener (17), and disconnect coolant pipe (18) from intake manifold.




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

Installation
1. Install new intake manifold gasket (1) to cylinder head.




2. Install intake manifold (2) with throttle body. Tighten bolts and nuts to specified torque.

Tightening torque
Intake manifold bolt and nut a: 25 N.m (2.5 kg-m, 18.0 lb-ft)




3. Connect coolant pipe (1) to intake manifold and install rear stiffener (2). Tighten bolts to specified torque.

Tightening torque
Intake manifold rear stiffener bolt a: 25 N.m (2.5 kg-m, 18.0 lb-ft)

4. Install intake manifold front stiffener (1). Tighten bolts to specified torque.

Tightening torque
Intake manifold front stiffener bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)

5. Connect the following hoses:
- Brake booster hose (2) to intake manifold
- PCV hose (3) to PCV valve
- Fuel pressure regulator vacuum hose (4) to intake manifold
- Coolant hoses (5) to throttle body
- Breather hose (6) to throttle body
- Vacuum hose (7) to EVAP canister purge valve
6. Connect the following electric lead wires:
- IAC valve (8)
- TP sensor (9)
- EGR valve (10)
- EVAP canister purge valve (11)
- MAP sensor (12)
- Ground terminal (13) to throttle body




7. Connect accelerator cable (14) to throttle valve lever (15) and install its bracket (16) to intake manifold.
Adjust accelerator cable play.
8. Install air cleaner outlet hose.
9. Install engine cover.
10. Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
11. Refill cooling system.
12. Connect negative cable at battery.
13. Start engine and check for engine coolant leaks.