Intake Manifold Replacement

Intake Manifold Replacement

Removal Procedure




1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).
2. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Radiator Hose).
3. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator control (TAC).
4. Disconnect the engine wiring harness electrical connector (2) from the generator starter.
5. Disconnect the engine wiring harness electrical connector (4) from the generator starter.
6. Remove the fuel injector wiring harness electrical connector retainer (6) from the generator starter.
7. Disconnect the fuel injector wiring harness electrical connector (7) from the engine wiring harness electrical connector (8).
8. Remove the engine wiring harness clips (5) from the intake manifold.




9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
10. Remove the vacuum brake booster hose (2) from the intake manifold.
11. Remove the throttle body. Refer to Throttle Body Assembly Replacement (Removal and Replacement).
12. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.




13. 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).
14. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement (Service and Repair).
15. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (Service and Repair).




16. Remove the 3-phase voltage cable bracket bolt (1) at the oil level indicator tube.




17. Remove the generator starter bolts.
18. Reposition and secure the generator starter out of the way.




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




20. Remove the intake manifold upper bolt and nuts.
21. Remove the intake manifold.

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

22. 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). Tighten the bolts/nuts (1) to 10 Nm (89 lb in).




5. Position the starter/generator to the bracket.
6. Install the starter/generator bolts until snug.
7. Tighten the starter generator bolts in the following sequence:

1. Front
2. Bottom
Tighten the bolts to 58 Nm (43 lb ft).




8. Install the 3-phase voltage cable bracket to the tie bar.
9. Install the 3-phase voltage cable bracket bolt (1) at the oil level indicator tube. Tighten the bolt to 10 Nm (89 lb in).




10. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (Service and Repair).
11. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement (Service and Repair).
12. 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).
13. Connect the engine wiring harness electrical connector to the MAP sensor.
14. Install the throttle body. Refer to Throttle Body Assembly Replacement (Removal and Replacement).




15. Install the vacuum brake booster hose (2) to the intake manifold.
16. Position the vacuum brake booster hose clamp (1) at the intake manifold.




17. Install the engine wiring harness clips (5) to the intake manifold.
18. Connect the fuel injector wiring harness electrical connector (7) to the engine wiring harness electrical connector (8).
19. Install the fuel injector wiring harness electrical connector retainer (6) to the generator starter.
20. Connect the engine wiring harness electrical connector (4) to the generator starter.
21. Connect the engine wiring harness electrical connector (2) to the generator starter.
22. Connect the engine wiring harness electrical connector (1) to the TAC.
23. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Radiator Hose).
24. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).