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. Disconnect the Mass Airflow (MAP) sensor electrical connector (4).
2. Disengage the cover clips (2).
3. Remove the air cleaner cover (1).





4. Loosen the air intake duct clamp at the throttle body.
5. Remove the air intake duct and air cleaner element.
6. Relieve the fuel system pressure.





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





8. Remove the EGR pipe bolts from the EGR bracket.





9. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.





10. Remove the Connector Position Assurance (CPA) retainer from the following electrical connectors:
^ Fuel injector harness (2)
^ Ignition coil harness (3)

11. Disconnect the following electrical connectors:
^ Air Conditioning (A/C) compressor high pressure recirculate switch (1)
^ Fuel injector harness (2)
^ Ignition coil harness (3)
^ A/C compressor high pressure cutoff switch (4)
^ A/C compressor clutch switch (5)

12. Remove the A/C compressor and condenser hose.





13. Disconnect the following electrical connectors:
^ Engine Coolant Temperature (ECT) sensor (1)
^ Ignition coil harness (2)





14. Disconnect the following electrical connectors:
^ Throttle Position (TP) sensor (2)
^ Electronic Throttle Control (ETC) (3)
^ Evaporative Emission (EVAP) purge solenoid (4)

15. Remove the wiring harness bolts.
16. Reposition the engine wiring harness.





17. If equipped with Regular Production Option (RPO) C5B, disconnect the EVAP canister tube from the purge solenoid.
18. Disconnect the EVAP canister tube from the canister.
19. Remove the EVAP canister tube.





20. If equipped without RPO C5B, disconnect the EVAP canister tube from the purge solenoid.





21. If equipped without RPO C5B, remove the EVAP canister tube clip from the fuel rail.
22. Disconnect the EVAP canister tube from the canister.
23. Disconnect the fuel line quick connect fittings.





24. Remove the intake manifold bolts.

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

25. Remove the intake manifold.

Important: The intake manifold gaskets are not reusable.





26. Remove and discard the intake manifold side gaskets.





27. Remove and discard the lower 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.





28. Remove the intake manifold oil splash shield.





29. If replacing the intake manifold, remove the EVAP purge solenoid bolt and purge solenoid.





30. If replacing the intake manifold, remove the MAP sensor bolt and sensor.
31. Inspect the MAP sensor seal for damage.





32. If replacing the intake manifold, remove the EGR bracket nuts, EGR bracket, and gasket.
33. Discard the EGR gasket.





34. If replacing the intake manifold, remove the throttle body nuts, throttle body, and gasket.
35. Discard the gasket.





36. If replacing the intake manifold, remove the fuel pressure regulator vacuum hose.





37. If replacing the intake manifold, remove the fuel rail studs and fuel rail.