Intake Manifold: Service and Repair

Intake Manifold

Intake Manifold (View 1 of 4)









Intake Manifold (View 2 of 4)









Intake Manifold (View 3 of 4)









Intake Manifold (View 4 of 4)









Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Disconnect the fuel tube spring lock coupling. For additional information, refer to Fuel System - General Information Service and Repair.

3. Disconnect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

4. Drain the engine cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.

5. Remove the Air Cleaner (ACL) and outlet pipe. For additional information, refer to Intake Air Distribution and Filtering Air Cleaner Air Cleaner Outlet Pipe.

6. Remove the wiper mounting arm and pivot shaft. For additional information, refer to Wipers and Washers Service and Repair.

7. Remove the 5 retainer screws, 2 Evaporative Emission (EVAP) canister purge valve bracket nuts and the RH cowl extension.

8. Disconnect the wiring harness electrical connector and remove the 3 retainer screws and the LH cowl extension.

9. Disconnect the 8 fuel injector electrical connectors.

10. Remove the 8 ignition coil-on-plugs. For additional information, refer to Engine Ignition - 4.6L (2V) Ignition Coil-On-Plug.

11. Remove the 2 intake manifold shield bolts and the shield.

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

13. Disconnect the EVAP canister purge valve hose quick connect couplings from the Throttle Body (TB) spacer and from the EVAP canister purge valve. For additional information, refer to Fuel System - General Information Service and Repair.

14. Disconnect the PCV tube quick connect coupling from the TB spacer. For additional information, refer to Fuel System - General Information Service and Repair.

15. Disconnect the EGR system module vacuum and electrical connectors.

16. Disconnect the intake manifold-to- TB spacer vacuum hose.

17. Disconnect the generator electrical connector.

18. Detach the 2 generator wiring harness retainers from the generator bracket.

19. Remove the 4 generator bracket bolts and the bracket.

20. Remove the coolant thermostat. For additional information, refer to Engine Cooling Service and Repair.

21. Disconnect the throttle control and the Throttle Position (TP) sensor electrical connector.

22. Release the heater hose spring clamp and disconnect the heater hose.

23. Remove the EGR system module tube. For additional information, refer to Engine Emission Control Service and Repair.

24. Detach the wire harness retainer from the intake manifold crash bracket.

25. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.





26. Remove the intake manifold crash bracket bolt.

27. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.

28. Remove the wire harness retainer from the rear of the intake manifold.

29. Remove the 8 bolts and the intake manifold.

30. Remove and discard the intake manifold gaskets.

31. Clean the sealing surfaces.

Installation

1. NOTE: Align the gasket locator tabs with the slots in the cylinder head.

Install new intake manifold gaskets.





2. 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.

Install the intake manifold and hand-tighten the 8 bolts.

3. Install the 8 ignition coil-on-plugs. For additional information, refer to Engine Ignition - 4.6L (2V) Ignition Coil-On-Plug.

4. Position the intake manifold crash bracket and loosely install the bolts.

5. Tighten the intake manifold bolts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).





6. Tighten the intake manifold crash bracket bolt.
- Tighten to 25 Nm (18 lb-ft).

7. Install the EGR system module tube. For additional information, refer to Engine Emission Control Service and Repair.

8. Install the intake manifold shield and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

9. Connect the throttle control and the TP sensor electrical connectors.

10. Install the coolant thermostat. For additional information, refer to Engine Cooling Service and Repair.

11. Install the generator bracket and the 4 bracket bolts.
- Tighten to 10 Nm (89 lb-in).

12. Connect the generator electrical connector.

13. Attach the 2 generator wiring harness retainers to the generator bracket.

14. Connect the EVAP canister purge valve hose quick connect couplings to the TB and the EVAP canister purge valve. For additional information, refer to Fuel System - General Information Service and Repair.

15. Connect the intake manifold vacuum hose to the TB spacer.

16. Connect the EGR system module vacuum and electrical connectors.

17. Connect the PCV tube quick connect coupling to the TB spacer. For additional information, refer to Fuel System - General Information Service and Repair.

18. Connect the brake booster vacuum hose to the intake manifold.

19. Install the heater hose and spring clamp.

20. Connect the fuel rail pressure and temperature sensor vacuum and electrical connectors.

21. Connect the 8 fuel injector electrical connectors.

22. Install the wire harness retainer to the rear of the intake manifold.

23. Attach the wire harness retainer to the intake manifold crash bracket.

24. Install the LH cowl extension and the 3 retainer screws and connect the wiring harness electrical connector.

25. Install the RH cowl extension, 5 retainer screws and the 2 EVAP canister purge valve bracket nuts.
- Tighten the nuts to 6 Nm (53 lb-in).

26. Install the wiper mounting arm and pivot shaft. For additional information, refer to Wipers and Washers Service and Repair.

27. Connect the fuel spring lock coupling. For additional information, refer to Fuel System - General Information Service and Repair.

28. Install the ACL and outlet pipe. For additional information, refer to Intake Air Distribution and Filtering Air Cleaner Air Cleaner Outlet Pipe.

29. Connect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

30. Fill and bleed the engine cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.