Intake Manifold: Service and Repair
Intake Manifold ReplacementRemoval Procedure
1. Remove the left engine splash shield.
2. Remove the right engine splash shield.
3. Drain the cooling system.
4. Remove the engine cover.
Caution: Refer to Battery Disconnect Caution in Service Precautions.
5. Disconnect the negative battery cable.
6. Remove the intake manifold insulator.
7. Disconnect the EVAP hose for the ORVR.
8. Disconnect the brake booster vacuum hose.
9. Disconnect the PCV hose.
10. Remove the 1 bolt and 1 nut from the accelerator cable bracket.
11. Disconnect the ECT sensor connector.
12. Disconnect the camshaft position sensor connector.
13. Disconnect the Camshaft Position (CMP) actuator solenoid valve connector.
14. Disconnect the rocker arm (CMP) control solenoid valve connector.
15. Disconnect the oil pressure switch and 2 ground connectors.
16. Unclip the engine wire harness from the top of the generator.
17. Remove 1 bolt from the engine wire harness bracket.
18. Remove the oil dipstick guide bolt.
19. Remove 2 bolts and 1 nut from the intake manifold bracket.
20. Remove 2 bolts from the alternator bracket.
21. Remove the intake manifold bolts and nuts.
22. Remove the intake manifold and gasket.
23. Remove the intake manifold insulator.
Installation Procedure
1. Install the intake manifold and new gasket.
Notice: Refer to Fastener Notice in Service Precautions.
2. Install the intake manifold bolts and nuts.
^ Tighten the upper intake manifold nuts and bolts to 34 Nm (25 ft. lbs.).
^ Tighten the lower intake manifold bolt to 46 Nm (34 ft. lbs.).
3. Install the alternator bracket and 2 bolts.
^ Tighten the alternator bracket bolts to 29 Nm (21 ft. lbs.).
4. Install the intake manifold bracket with 2 bolts and 1 nut.
^ Tighten the intake manifold bracket bolts and nut to 24 Nm (18 ft. lbs.).
5. Install the oil dipstick guide tube and bolt.
^ Tighten the oil dipstick guide tube bolt to 24 Nm (18 ft. lbs.).
6. Install 1 bolt to the engine wire harness bracket.
^ Tighten the engine wire harness bracket bolts to 10 Nm (7 ft. lbs.).
7. Clip the engine wire harness to the top of the generator.
8. Connect the oil pressure switch and 2 ground connectors.
9. Connect the rocker arm (CMP) control solenoid valve connector.
10. Connect the Camshaft Position (CMP) actuator solenoid valve connector.
11. Connect the camshaft position sensor connector.
12. Connect the ECT sensor connector.
13. Install the 1 bolt and 1 nut to the accelerator cable bracket.
^ Tighten the accelerator cable bracket bolts to 13 Nm (10 ft. lbs.).
14. Connect the PCV hose.
15. Connect the brake booster vacuum hose.
16. Connect the EVAP hose for the ORVR.
17. Install the intake manifold insulator.
18. Install the engine cover.
19. Install the right engine splash shield.
20. Install the left engine splash shield.
21. Refill the cooling system.
22. Connect the negative battery cable.