Intake Manifold: Service and Repair

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. Remove the throttle body.
2. Remove the fuel injectors.




3. Disconnect the following electrical connectors:
^ Manifold absolute pressure (MAP) sensor (1)
^ Knock sensor (2)
4. Remove the knock sensor harness electrical connector from the intake manifold.
5. Set the electrical harness aside.




6. Disconnect the electronic temperature control (ETC) connector.




7. Remove the positive crankcase ventilation (PCV) hose.




8. Remove the MAP sensor (1) from the intake manifold.
9. Remove the engine coolant air bleed clamp and hose from the throttle body, if applicable.




10. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:

1. Remove the EVAP tube end (2) from the solenoid (1).
2. Squeeze the EVAP pipe quick connect fitting (3) retainer together.
3. Remove the EVAP tube end (3) from the vapor pipe.




11. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold.




12. Remove the intake manifold bolts.
13. Remove the intake manifold.




14. Remove the intake manifold gaskets (1) from the intake manifold.
15. Discard the old intake manifold gaskets.

Installation Procedure




1. Install new intake manifold gaskets (1) to the intake manifold.




2. Install the intake manifold.
3. Apply a 5 mm (0.20 in) band of threadlock to the threads of the intake manifold bolts. Refer to Sealers, Adhesives, and Lubricants for the correct part number.





Notice: Refer to Fastener Notice.

4. Install the intake manifold bolts.

1. Tighten the intake manifold bolts a first pass in sequence to 5 N.m (44 lb in).
2. Tighten the intake manifold bolts a final pass in sequence to 10 N.m (89 lb in).




5. Install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold.

Tighten the EVAP purge solenoid bolt to 10 N.m (89 lb in).




6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe.
7. Install the engine coolant air bleed clamp and hose to the throttle body, if applicable.





Important: Lightly coat the MAP sensor seal with clean engine oil before installing.

8. Install the MAP sensor (1) to the intake manifold.




9. Install the PCV hose.




10. Connect the knock sensor harness electrical connector to the intake manifold.
11. Connect the following electrical connectors.
^ MAP sensor (1)
^ Knock sensor (2)
^ exhaust gas recirculation (EGR) valve, if equipped
12. Install the fuel injectors.
13. Install the throttle body.