Intake Manifold Replacement

Removal Procedure





1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
2. Carefully disconnect the throttle body air inlet duct from the throttle body. Refer to Air Cleaner Intake Duct Replacement in Powertrain Management.
3. Partially drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
5. Disconnect the accelerator and cruise control cables from the throttle body and accelerator cable bracket. Refer to Accelerator Controls Cable Replacement and Cruise Control Cable Replacement in Powertrain Management.
6. Disconnect the throttle body coolant hoses from the throttle body. Refer to Throttle Body Heater Hose Replacement - Inlet and Throttle Body Heater Hose Replacement - Outlet in Cooling System.





7. Disconnect the fuel lines from the throttle body. Refer to Fuel Pressure Relief Procedure and Quick Connect Fitting(s) Service (Metal Collar) or Quick Connect Fitting(s) Service (Plastic Collar) in Powertrain Management.





8. Disconnect the fuel vapor line from the EVAP canister purge solenoid. Refer to EVAP Canister Purge Valve Replacement in Powertrain Management.





9. Disconnect the brake booster vacuum hose from the brake booster. Refer to Vacuum Brake Booster Hose Replacement in Brakes and Traction Control.





10. Disconnect the A/C vacuum hose from the intake manifold.
11. Disconnect the surge tank inlet pipe retainer from the fuel injector rail.
12. Disconnect the fuel injector wiring harness connectors. Refer to Engine Control Component Views in Powertrain Management.
13. Disconnect the engine wiring harness connectors from the following components: Refer to Engine Control Component Views in Powertrain Management.
^ Throttle Position (TP) sensor
^ Idle Air Control (IAC) valve
^ EVAP canister purge solenoid
^ Manifold Absolute Pressure (MAP) sensor
14. Remove the engine wiring harness channel bolts from the camshaft covers. Refer to Engine Control Component Views in Powertrain Management.
15. Remove and set aside the engine wiring harness and channel. Refer to Engine Control Component Views in Powertrain Management.





16. Disconnect the fuel pressure regulator vacuum tube (1) from the regulator (2) and the throttle body (3).





17. Disconnect and remove the PCV valve and both feed tubes (1, 2) from the camshaft covers and intake manifold.





18. Remove the EGR valve outlet pipe retaining bolts from the intake manifold and the water crossover.
19. Remove the EGR valve outlet pipe.





20. Disconnect the four fuel rail snap-lock retainers by pushing toward the camshaft covers and lifting.
21. Remove the fuel rail (1) and fuel injectors (2) as an assembly and store in a clean, secure location away from any heat sources.





22. Remove the intake manifold bolts.





23. Disconnect the throttle body coolant hose from the water crossover feed tube (1).





24. Remove the intake manifold.

Important: It you are NOT replacing the intake manifold skip the following steps.

25. If necessary, disassemble the intake manifold. Refer to Intake Manifold Disassemble in Engine / Service and Repair / Unit Repair.
26. Clean and inspect the intake manifold. Refer to Intake Manifold Clean and Inspect in Engine / Service and Repair / Unit Repair.

Installation Procedure





1. It necessary, assemble the intake manifold. Refer to Intake Manifold Assemble in Engine / Service and Repair / Unit Repair.
2. Install the intake manifold.





3. Connect the throttle body heater hose to the water crossover feed tube (1).
4. Install the hose clamp.

Notice: Refer to Fastener Notice in Service Precautions.

Important: Tighten the intake manifold bolts in circular pattern starting from the center and moving outward.





5. Install the intake manifold bolts.
Tighten the intake manifold bolts to 7 Nm (62 inch lbs.).





6. Inspect the fuel injector O-rings (2) for misalignment or damage. Replace the O-rings if necessary.

Important: Do not apply excessive pressure to the fuel rail when installing. If excessive pressure is needed to install the fuel rail then misalignment of a fuel injector could be the concern and using excessive pressure will only cause damage to the seal or intake manifold.

7. Install the fuel rail (1) and fuel injectors (2) by aligning the fuel injectors with their respective ports and pressing the four fuel rail snap-lock connectors into the intake manifold until they lock in place.





8. Install a new EGR outlet pipe.
9. Install the EGR outlet pipe to intake manifold bolt.
Tighten the EGR outlet pipe to intake manifold bolt to 10 Nm (89 inch lbs.).
10. Install the EGR outlet pipe to water crossover bolt.
Tighten the EGR outlet pipe to water crossover bolt to 24 Nm (18 ft. lbs.).





11. Install the PCV valve and connect both feed tubes (1, 2) to the camshaft covers and intake manifold.





12. Connect the brake booster vacuum hose to the brake booster. Refer to Vacuum Brake Booster Hose Replacement in Brakes and Traction Control.





13. Connect the fuel pressure regulator vacuum tube (1) to the regulator (2) and the throttle body (3).





14. Connect the A/C vacuum hose to the intake manifold.
15. Install the engine wiring harness and channel. Refer to Engine Control Component Views in Powertrain Management.
16. Install the engine wiring harness channel bolts to the camshaft covers. Refer to Engine Control Component Views in Powertrain Management.
Tighten the engine wiring harness channel bolts to 10 Nm (89 inch lbs.).
17. Connect the surge tank inlet pipe retainer to the fuel injector rail.
18. Connect the engine wiring harness connectors to the following components:
Refer to Engine Control Component Views in Powertrain Management.
^ Throttle position (TP) sensor
^ Idle air control (IAC) valve
^ EVAP canister purge solenoid
^ Manifold absolute pressure (MAP) sensor
19. Connect the fuel injector wiring harness connectors. Refer to Engine Control Component Views in Powertrain Management.
20. Connect the throttle body coolant hoses to the throttle body. Refer to Throttle Body Heater Hose Replacement - Inlet and Throttle Body Heater Hose Replacement - Outlet in Cooling System.
21. Connect the accelerator and cruise control cables to the throttle body and accelerator cable bracket. Refer to Accelerator Controls Cable Replacement and Cruise Control Cable Replacement in Powertrain Management.





22. Connect the fuel lines to the throttle body. Refer to Quick Connect Fitting(s) Service (Metal Collar) or Quick Connect Fitting(s) Service (Plastic Collar) in Powertrain Management.





23. Connect the fuel vapor line to the EVAP canister purge solenoid. Refer to EVAP Canister Purge Valve Replacement in Powertrain Management.





24. Install the fuel injector sight shield (3). Refer to Fuel Injector Sight Shield Replacement.
25. Carefully connect the throttle body air inlet duct to the throttle body. Refer to Air Cleaner Intake Duct Replacement in Powertrain Management.
26. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
27. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.