Intake Manifold: Service and Repair

Intake Manifold













Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction.

2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.

3. Remove the fuel rail and injectors. For additional information, refer to Fuel Delivery and Air Induction.

4. Disconnect the Electronic Throttle Body (ETB) electrical connector.

5. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.

6. Disconnect the Throttle Position (TP) sensor electrical connector.

7. Disconnect the PCV hose from the heated PCV fitting on the intake manifold.

8. Disconnect the heated PCV fitting electrical connector.

9. Detach the wiring harness retainers from the intake manifold.

10. Disconnect the Charge Motion Control Valve (CMCV) electrical connector.

11. Remove the 10 bolts and position the intake manifold forward.

12. Disconnect the brake booster vacuum hose from the rear of the intake manifold.

13. Disconnect the vacuum hose from the rear of the intake manifold.

14. Remove the intake manifold and the gaskets.
- Discard the gaskets.

Installation

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old gaskets.

NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at the rear of the intake manifold. Use extreme care during the installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.

Using new intake manifold gaskets, position the intake manifold.

2. Connect the vacuum hose to the rear of the intake manifold.

3. Connect the brake booster hose to the rear of the intake manifold.

4. Install the 10 intake manifold bolts and tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten finger-tight.

- Stage 2: Tighten to 10 Nm (89 lb-in).

- Stage 3: Tighten an additional 60 degrees.

- Stage 4: Loosen all 10 bolts a minimum of 1 full turn (360 degrees).

- Stage 5: Tighten to 10 Nm (89 lb-in).

- Stage 6: Tighten an additional 60 degrees.





5. Connect the CMCV electrical connector.

6. Attach the wiring harness retainers to the intake manifold.

7. Connect the heated PCV fitting electrical connector.

8. Connect the PCV hose to the heated PCV fitting on the intake manifold.

9. Connect the TP sensor electrical connector.

10. Connect the EVAP hose to the intake manifold.

11. Connect the ETB electrical connector.

12. Install the fuel rail and injectors. For additional information, refer to Fuel Delivery and Air Induction.

13. Install the ACL outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.