Intake Manifold: Service and Repair

Intake Manifold Removal and Installation

Exploded View





Removal

1. Relieve the fuel pressure Service and Repair.

2. Remove the charge air cooler Service and Repair.

3. Remove the fuel injector cover.






4. Disconnect the engine wire harness connectors, and remove the wire harness clamps from the intake manifold.

- Four injector connectors
- Throttle body connector
- MAP sensor connector
- IAT sensor connector
- Turbocharger bypass control solenoid valve connector

5. Remove the quick-connect fitting cover (A), then disconnect the fuel feed hose Fuel Line/Quick-Connect Fitting Removal.






6. Disconnect the vacuum hoses (A) and the brake booster vacuum hose (B).





7. Remove the ground cable (C) and the turbocharger bypass control solenoid valve bracket mounting bolt (D).

8. Disconnect the EVAP canister hose (A) and remove the water bypass line bracket mounting bolt (B).





9. Disconnect the water bypass hoses (C), then plug the water bypass hoses.

10. Disconnect the PCV hose (A) and remove the harness holder (B).






11. Remove the harness clamp (A) and the connector (B), then remove the intake manifold bracket (C).






12. Remove the intake manifold assembly.






13. Refer to the Exploded View needed during this procedure.

Installation

1. Refer to the Exploded View needed during this procedure.

2. Install the intake manifold (A) with a new gasket (B), then tighten the bolts and nuts in a crisscross pattern in three steps, beginning with the inner bolt.






3. Install the intake manifold bracket (A), then install the harness clamp (B) and the connector (C).






4. Connect the PCV hose (A) and install the harness holder (B).






5. Connect the water bypass hoses (A) and the EVAP canister hose (B).





6. Install the water bypass line bracket mounting bolt (C).

7. Install the ground cable (A) and the turbocharger bypass control solenoid valve bracket mounting bolt (B).





8. Connect the vacuum hoses (C) and the brake booster vacuum hose (D).

9. Connect the fuel feed hose Fuel Line/Quick-Connect Fitting Removal, then install the quick-connect fitting cover (A).






10. Connect the engine wire harness connectors, and install the wire harness clamps to the intake manifold.

- Four injector connectors
- Throttle body connector
- MAP sensor connector
- IAT sensor connector
- Turbocharger bypass control solenoid valve connector

11. Install the injector cover.






12. Install the charge air cooler Service and Repair.

13. After installation, check that all tubes, hoses, and connectors are installed correctly.

14. Clean up any spilled engine coolant.

15. Inspect for fuel leaks: Turn the ignition switch to ON (II) (do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

16. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open Service and Repair.