Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure





1. Disconnect the negative battery cable.
2. Remove the upper fan shroud.
3. Disconnect the power brake booster vacuum hose.
4. Remove the air cleaner outlet resonator.





5. Disconnect the following electrical connectors:
^ Idle air control (IAC) motor (1)
^ Manifold absolute pressure (MAP) sensor (4)
^ Throttle position (TP) sensor (2)
^ Engine coolant temperature (ECT) sensor (3)





6. Disconnect the fuel injector harness electrical connector.
7. Remove the fuel injector harness electrical connector from the bracket on the valve rocker arm cover.
8. Remove the engine wiring harness from the bracket.
9. Move and secure the engine wiring harness out of the way.





10. Disconnect the heating and air conditioning control vacuum source hose.
11. Disconnect the EVAP emission purge tube from the throttle body.





12. Remove the bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.
13. Remove the nut holding the engine wiring harness clip to the intake manifold.
14. Remove the nut holding the engine wiring harness clip to the intake manifold rear lower stud.
15. Disconnect the fuel hose from the fuel rail.
16. Remove the accelerator control cable from the throttle body.
17. Remove the cruise control cable from the throttle body.





18. Remove the spark plug wires from the spark plugs.
19. Remove the spark plug wire harness retainer from the thermostat assembly and set aside the spark plug wire harness.





20. Remove the right fender wheelhouse extension.





21. Working through the wheelhouse, remove the generator rear brace from the engine.
^ Remove the nuts holding the brace to the intake stud and the engine block.
^ Remove the bolt holding the brace to the rear of the generator.





22. Remove the engine wiring harness bracket at the back of the engine using the following procedure:
22.1. Loosen the bolt at the rear of the cylinder head.
22.2. Remove the 2 bolts that secure the bracket to the valve rocker arm cover.
22.3. Slide the bracket off of the bolt at the rear of the cylinder head.





23. Remove the intake manifold bolts.
24. Remove the intake manifold nuts.
25. Remove the fuel rail bracket.
26. Remove the intake manifold.
27. If replacing the intake manifold remove the following:
^ The throttle body
^ The fuel rail
28. Clean the intake manifold mating surfaces.
29. Inspect the intake manifold for damage.
30. Inspect the intake manifold for cracks near compression limiters.
31. Inspect the crankcase ventilation passages in the intake manifold face for blockage and clean as necessary.
32. Replace the intake manifold as necessary.

Installation Procedure





1. Install the fuel rail if removed.
2. Install the throttle body if removed.
3. Install the intake manifold gasket.
4. Install the intake manifold.

Notice: Refer to Fastener Notice in Service Precautions.

Intake Manifold Tightening Sequence:

5. Install the intake manifold bolts.
^ Tighten the bolts in sequence to 24 Nm (17 ft. lbs.).





6. Install the engine wire harness bracket to the rear of the engine using the following procedure:
6.1. Slide the bracket over the bolt at the rear of the cylinder head.
6.2. Install the 2 bolts that secure the bracket to the valve rocker arm cover.
7. Tighten the bolts in the following order:
7.1. Tighten the 2 bolts to the valve rocker arm cover to 10 Nm (89 inch lbs.).
7.2. Tighten the bolt at the rear of the cylinder head to 25 Nm (18 ft. lbs.).





8. Working through the wheelhouse, install the generator rear brace.
9. Install the nuts holding the brace to the intake manifold stud and the stud on the engine.
10. Install the bolt holding the brace to the rear of the generator.
^ Tighten the generator rear brace nuts and bolts to 25 Nm (18 ft. lbs.).





11. Position the spark plug wire harness.
12. Install the spark plug wire harness retainer on the thermostat assembly.
13. Install the spark plug wires to the spark plugs.
14. Install the accelerator control cable to the throttle body.
15. Install the cruise control cable to the throttle body.
16. Connect the fuel hose to the fuel rail.





17. Install the bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.
^ Tighten the bolts to 10 Nm (89 inch lbs.).
18. Install the nut holding the engine wiring harness clip and the negative battery cable clip to the intake manifold.
^ Tighten the engine wiring harness clip nut to 10 Nm (89 inch lbs.).
19. Install the nut holding the engine wiring harness clip to the intake manifold rear lower stud.
^ Tighten the engine wiring harness clip nut to 30 Nm (89 inch lbs.).





20. Connect the heating and air conditioning control vacuum source hose.
21. Connect the EVAP emission purge tube to the throttle body.





22. Position the engine wiring harness.
23. Install the engine wiring harness to the bracket.
24. Install the fuel injector harness electrical connector to the bracket on the valve rocker arm cover.
25. Connect the fuel injector harness electrical connector.





26. Connect the following electrical connectors:
^ Idle air control (IAC) motor (1)
^ Manifold absolute pressure (MAP) sensor (4)
^ Throttle position (TP) sensor (2)
^ Engine coolant temperature (ECT) sensor (3).





27. Install the right fender wheelhouse extension.
28. Install the air cleaner outlet resonator.





29. Install the upper fan shroud.
30. Connect the power brake booster vacuum hose.
31. Connect the negative battery cable.