Intake Manifold: Service and Repair

Intake Manifold Replacement
Removal Procedure





1. Remove the air cleaner assembly.
2. Disconnect the throttle actuator control (TAC) electrical connector (1).
3. Disconnect the fuel injector electrical connector (2).





4. If equipped with a manual transaxle, disconnect the engine harness clips (2 and 4) from the intake manifold.
5. Disconnect the engine harness clip (1) from the oil level indicator tube.
6. Disconnect the fuel injector electrical connector clip (3) from the intake manifold.





7. If equipped with a automatic transaxle, disconnect the engine harness clips (2 and 4) from the intake manifold.
8. Disconnect the engine harness clip (2) from the oil level indicator tube.
9. Disconnect the fuel injector electrical connector clip (4) from the intake manifold.





10. Remove the throttle body bolts.

11. Important: The throttle body seal is reusable, only replace the seal if damaged.

Remove the throttle body and seal.
12. Remove and inspect the throttle body seal.





13. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid.
14. Remove the oil level indicator tube.
15. Remove the fuel rail.





16. Remove the intake manifold lower bolts (1).





17. Remove the intake manifold upper bolt and nuts.
18. Remove the intake manifold.

19. Important: The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

Remove and inspect the intake manifold gasket.

Installation Procedure





1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.
2. Install the intake manifold.
3. Install the intake manifold upper bolt and nuts.





4. Notice: Refer to Fastener Notice.

Install the intake manifold lower bolts (1).
Tighten the bolts/nuts to 10 Nm (89 inch lbs.).





5. Install the fuel rail.
6. Install the oil level indicator tube.
7. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid.





8. Install a NEW throttle body seal if necessary, otherwise install the old seal.
9. Position the throttle body.
10. Install the throttle body bolts.
Tighten the bolts to 10 Nm (89 inch lbs.).





11. If equipped with a automatic transaxle, connect the engine harness clips (2 and 4) to the intake manifold.
12. Connect the engine harness clip (2) to the oil level indicator tube.
13. Connect the fuel injector electrical connector clip (4) to the intake manifold.





14. If equipped with a manual transaxle, connect the engine harness clips (2 and 4) to the intake manifold.
15. Connect the engine harness clip (1) to the oil level indicator tube.
16. Connect the fuel injector electrical connector clip (3) to the intake manifold.





17. Connect the fuel injector electrical connector (2).
18. Connect the throttle actuator control (TAC) electrical connector (1).
19. Install the air cleaner assembly.