Intake Manifold Removal

Intake Manifold Replacement

Removal Procedure

Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.





1. Loosen the clamps at the throttle body and air cleaner.
2. Remove the air cleaner outlet duct.





3. Loosen the intake manifold sight shield bolt (3).
4. Remove the sight shield from the bracket (1).
5. Remove the sight shield bracket (1) and nuts.
6. Relieve the fuel system pressure.
7. Disconnect the fuel feed and return pipes.





8. Disconnect the engine harness clips from the studs on the front of dash.
9. Disconnect the engine harness clip from the wheelhouse splash shield.
10. Disconnect the following electrical connectors:
^ Pressure cycling switch (1)
^ Surge tank switch (2)
^ Mass Air Flow (MAF) sensor (3)
11. Reposition engine harness branch to top of engine.





12. Remove the Connector Position Assurance (CPA) retainer at the ignition coil harness.
13. Disconnect the following electrical connectors:
^ Manifold Absolute Pressure (MAP) sensor (1)
^ Ignition coil harness (2)
^ Engine Coolant Temperature (ECT) sensor (3)





14. Remove the engine harness bolt and studs
15. Remove the CPA retainer at the ignition coil harness.
16. Disconnect the following electrical connectors:
^ Generator (1)
^ Injector harness (2)
^ Ignition coil harness (3)
^ Throttle Position (TP) sensor (4)
^ Electronic Throttle Control (ETC) (5)
^ Purge valve solenoid (6)
17. Reposition the engine harness to the drivers side of the engine compartment.





18. Remove the bypass valve vacuum hose (1) from the intake manifold.





19. Disconnect the Exhaust Gas Recirculation (EGR) valve electrical connector (1).





20. Remove the EGR pipe bolts at the EGR adapter.
21. Reposition the EGR pipe.
22. Remove and discard the EGR valve pipe gasket.





23. Remove the secondary air injection (AIR) pipe nut from the fuel rail stud, if equipped.
24. Remove the AIR pipe bolts at the exhaust manifold, if equipped.
25. Disconnect the AIR pipe from the AIR pump pipe, if equipped.
26. Remove and discard the AIR pipe gasket.





27. Remove the AIR pipe nut from the fuel rail stud, if equipped.
28. Remove the AIR pipe bolts at the exhaust manifold, if equipped.
29. Disconnect the AIR pipe from the AIR pump pipe, if equipped.
30. Remove and discard the AIR pipe gasket.





31. Reposition the AIR pump hose clamp.
32. Remove the AIR pump hose (1) from the pump pipe.





33. Remove the AIR pump pipe bolt from the cylinder head, if equipped.
34. Remove the AIR pump pipe, if equipped.





35. Remove the fuel pressure regulator vacuum hose.
36. If replacing the intake manifold, remove the fuel rail studs.
37. Remove the fuel rail.





38. Remove the intake manifold bolts.





Important: Do not attempt to loosen the manifold by prying under the gasket surface with any tool.

39. Remove the intake manifold.





Important: The intake manifold gaskets are not reusable.

40. Remove and discard the intake manifold side gaskets.





41. Remove and discard the intake manifold end seals.





Important: The splash shield is secured using a snap-in fit. Do not distort the splash shield. The splash shield is reusable.

42. Remove the splash shield.
43. If replacing the intake manifold, refer to Intake Manifold Disassemble.
44. Clean the intake manifold.