Intake Manifold Replacement

Intake Manifold Replacement

Removal Procedure




1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (Intake Manifold Cover Replacement).
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).
3. Disconnect the engine harness electrical connector (1) from the throttle actuator control (TAC).
4. Disconnect the engine harness electrical connector (2) from the fuel injector harness.
5. Disconnect the engine harness electrical connector from the manifold absolute pressure (MAP) sensor.




6. Disconnect the engine harness clips (1 and 3) from the intake manifold.
7. Disconnect the engine harness clip (2) from the oil level indicator tube.
8. Disconnect the fuel injector electrical connector clip from the intake manifold.




9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
10. Remove the vacuum brake booster hose from the intake manifold.




11. Remove the throttle body bolts.

Note: The throttle body seal is reusable, only replace the seal if damaged.

12. Remove the throttle body and seal.
13. Remove and inspect the throttle body seal.




14. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
15. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement (Service and Repair).
16. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (Service and Repair).




17. Remove the intake manifold lower bolts (1).




18. Remove the intake manifold upper bolt and nuts.
19. Remove the intake manifold.

Note: The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

20. Remove and inspect the intake manifold gasket.

Installation Procedure




1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.
2. Install the intake manifold.
3. Install the intake manifold upper bolt and nuts.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the intake manifold lower bolts (1) and tighten to 10 Nm (89 lb in).




5. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (Service and Repair).
6. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement (Service and Repair).
7. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




8. Install a NEW throttle body seal if necessary, otherwise install the old seal.
9. Position the throttle body.
10. Install the throttle body bolts and tighten to 10 Nm (89 lb in).




11. Install the vacuum brake booster hose to the intake manifold.
12. Position the vacuum brake booster hose clamp (2) at the intake manifold.




13. Connect the engine harness clips (1 and 3) to the intake manifold.
14. Connect the engine harness clip (2) to the oil level indicator tube.
15. Connect the fuel injector electrical connector clip to the intake manifold.




16. Connect the engine harness electrical connector (2) to the fuel injector harness.
17. Connect the engine harness electrical connector to the MAP sensor.
18. Connect the engine harness electrical connector (1) to the TAC.
19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).
20. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (Intake Manifold Cover Replacement).