Intake Manifold: Service and Repair

REMOVAL
1. Disconnect negative cable at battery.





2. Drain coolant.

WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.

3. Remove strut tower bar.
4. Remove intake air temperature sensor.





5. Remove air cleaner upper case and air cleaner outlet hose as one component. Do not disassemble them, when removing and reinstalling.





6. Remove throttle cover.
7. Disconnect accelerator cable and A/T throttle cable (For A/T vehicle) from throttle body.





8. Disconnect following electric lead wires:
- EGR valve
- Idle Air Control (IAC) valve
- Throttle Position (TP) sensor
- Mass Air Flow (MAF) sensor
- EVAP canister purge valve
- Ground terminal from intake manifold
- EVAP diagnostic valve (if equipped)





9. Disconnect following hoses:
- Brake booster hose from intake manifold
- PCV hose from PCV valve
- Fuel pressure regulator vacuum hose from intake manifold
- Manifold Differential Pressure (MDP) sensor hose from intake manifold
- Canister purge hose from EVAP canister
- Water hoses from throttle body and water bypass pipe
- Breather hose from throttle body





10. Remove throttle body from intake manifold





11. Remove intake manifold front stiffener and rear stiffener.





12. Disconnect water pipe from intake manifold.





13. Remove intake manifold from cylinder head, and then its gasket.





14. Remove EVAP canister purge valve, EGR valve, IAC valve, EGR pipe and vacuum pipe from intake manifold.

INSTALLATION





1. Install EVAP canister purge valve, EGR valve, IAC valve, EGR pipe and vacuum pipe to intake manifold. Use new gaskets if equipped.





2. Install new intake manifold gasket to cylinder head.
3. Install intake manifold.
Tighten bolts and nuts to specified torque.

Tightening Torque (a): 23 Nm (17.0 ft. lbs.)





4. Connect water pipe to intake manifold.





5. Install intake manifold front stiffener and rear stiffener.
Tighten bolts to specified torque.

Tightening Torque
(a): 50 Nm (36.5 ft. lbs.)
(b): 23 Nm (17.0 ft. lbs.)





6. Install throttle body to intake manifold with new gasket.
Tighten bolts and nuts to specified torque.

Tightening Torque (a): 23 Nm (17.0 ft. lbs.)





7. Connect following hoses:
- Brake booster hose to intake manifold
- PCV hose to PCV valve
- Fuel pressure regulator vacuum hose to intake manifold or 3 way joint
- MDP sensor hose to intake manifold
- Canister purge hose to EVAP canister
- Water hoses to throttle body and water bypass pipe
- Breather hose to throttle body





8. Connect following electric lead wires:
- EGR valve
- IAC valve
- TP sensor
- MAF sensor
- EVAP canister purge valve
- Ground terminal to intake manifold
- EVAP diagnostic valve (if equipped)





9. Connect accelerator cable and A/T throttle cable to throttle body.
Adjust accelerator cable play and A/T throttle cable play.
10. Install throttle cover.
11. Install air cleaner upper case and air cleaner outlet hose.
12. Install air temperature (IAT) sensor to air cleaner box.





13. Install strut tower bar.
Tighten bolts and nuts to specified torque.

Tightening Torque (a): 25 Nm (18.0 ft. lbs.)

14. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
15. Refill cooling system.
16. Connect negative cable at battery.
17. Finally, start engine and check for engine coolant leaks.