Intake Manifold: Service and Repair

Intake Manifold

Throttle Cables and Electrical Connectors









Vacuum Hoses and Electrical Connectors









Spark Plug Wires and Ignition Coil









PCM Electrical Connectors









Intake Manifold









Removal and Installation

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.

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: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Disconnect the battery ground cable. For additional information, refer to Battery.

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

3. Disconnect the accelerator cable from the Throttle Body (TB).

4. If equipped, disconnect the speed control actuator cable from the TB.

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

6. Detach the wiring harness retainer.

7. Disconnect the Idle Air Control (IAC) motor electrical connector.

8. Disconnect the EGR valve vacuum hose connector.

9. Disconnect the exhaust manifold-to-EGR valve tube from the EGR valve.
- To install, tighten to 34 Nm (25 lb-ft).

10. Disconnect the Evaporative Emission (EVAP) purge valve-to-intake manifold hose from the intake manifold.

11. Disconnect the EGR vacuum regulator solenoid electrical connector.

12. Disconnect the EGR vacuum regulator solenoid vacuum connector.

13. Disconnect the brake booster vacuum hose from the intake manifold.

14. NOTICE: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.

NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark the spark plug wire locations before removing them.

Disconnect the RH spark plug wires from the ignition coil.

15. Detach the RH spark plug wire retainer from the intake manifold and position the spark plug wires aside.

16. Disconnect the ignition coil electrical connector.

17. Detach the wiring harness retainer from the ignition coil bracket.

18. Detach the accelerator cable retainer from the ignition coil bracket.

19. Disconnect the radio interference capacitor electrical connector.

20. Remove the 4 bolts and position the ignition coil and bracket aside.
- To install, tighten the lower rear bolt to 28 Nm (21 lb-ft).

- To install, tighten the lower front bolt to 23 Nm (17 lb-ft).

- To install, tighten the 2 upper bolts to 8 Nm (71 lb-in).

21. Disconnect the vacuum harness main vacuum connector from the intake manifold.

22. Remove the wiring harness-to-cowl bracket nut.

23. Disconnect the 3 PCM electrical connectors.

24. Remove the wiring harness ground wire stud bolt and position the wiring harness aside.
- To install, tighten to 10 Nm (89 lb-in).

25. Detach the Knock Sensor (KS) electrical connector from the intake manifold.

26. Loosen the 8 bolts and lift up the intake manifold.
- To install, tighten to 10 Nm (89 lb-in).

27. Remove the 2 heated PCV fitting bolts and detach the heated PCV fitting from the intake manifold.
- To install, tighten to 8 Nm (71 lb-in).

28. Remove the intake manifold.

29. Inspect the intake manifold gaskets. Install new gaskets if necessary.

30. 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.

To install, reverse the removal procedure.