Intake Manifold Replacement

Removal Procedure





1. Drain the cooling system.
2. Raise and suitably support the vehicle. Refer to Vehicle Lifting
3. Remove the transmission fluid level indicator tube bolt.
4. Lower the vehicle.
5. Relieve the fuel system pressure.

Important: Cap the fittings and plug the holes when separating fuel system components in order to prevent dripping of fuel and/or dirt and other contaminants from entering the fuel system.





6. Disconnect the fuel line from the fuel rail.
7. Disconnect the vapor line from the fuel vapor purge valve.





8. Disconnect the Intake Air Temperature (IAT) sensor electrical connector at the air intake duct.
9. Disconnect the Mass Airflow (MAF) sensor electrical connector at the air intake duct.





10. Remove the air intake duct from the throttle body and the air cleaner box.





11. Disconnect the Idle Air Control (IAC) valve electrical connector from the throttle body.
12. Disconnect the Throttle Position Sensor (TPS) electrical connector from the throttle body.
13. Remove the accessory drive belt.





14. Disconnect the Exhaust Gas Recirculation (EGR) solenoid electrical connector.





15. Remove the EGR valve pipe and solenoid.





16. Unsnap the cruise control cable from the throttle lever, if equipped.
- Push the cruise cable connector forward to unsnap.
- Unsnap the cable from the engine bracket.





17. Remove the accelerator cable from the throttle lever.





18. Remove the accelerator control cable and cruise control servo bracket.





19. Disconnect the right side fuel injector electrical connectors.





20. Disconnect the left side fuel injector electrical connectors.
21. Remove the fuel rail.





22. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
23. Disconnect the vacuum hose from the vacuum port on the MAP sensor housing.





24. Disconnect the knock sensor harness electrical connector (4).
25. Disconnect all the remaining electrical connections from the intake manifold.





26. Remove the knock sensor harness connector (1) from the fuel rail stop bracket (2).





27. Remove the Positive Crankcase Ventilation (PCV) valve pipe from the rocker cover.





28. Remove the PCV valve pipe strap nut.
29. Remove the PCV valve pipe from the rocker cover.





30. Remove the fresh air tube from the throttle body and rocker cover.





31. Remove the vapor vent tube hose from the throttle body.





32. Remove the throttle body heater outlet hose from the throttle body.





33. Remove the Evaporative Emission (EVAP) canister purge tube.





34. Remove the canister purge valve and bracket from the intake manifold.
35. Remove the intake manifold.

Installation Procedure
1. Install the intake manifold.





2. Install the canister purge valve and bracket to the intake manifold.





3. Install the EVAP canister purge tube.





4. Install the throttle body heater outlet hose to the throttle body.





5. Install the vapor vent tube hose to the throttle body.





6. Install the fresh air tube to the throttle body and rocker cover.





7. Connect the PCV valve pipe to the rocker cover.

Notice: Refer to Fastener Notice in Service Precautions.

8. Install the PCV pipe strap nut.
- Tighten the PCV pipe strap nut to 12 Nm (106 inch lbs.).





9. Install the PCV valve pipe to the rocker cover.





10. Connect the knock sensor harness connector (1) to the fuel rail stop bracket (2).





11. Connect the knock sensor harness electrical connector (4).





12. Connect the MAP sensor electrical connector.
13. Connect the vacuum hose to the vacuum port on the MAP sensor housing.





14. Connect the left side fuel injector electrical connectors.





15. Connect the right side fuel injector electrical connectors.
16. Connect all remaining electrical connectors to the intake manifold.





17. Install the accelerator control cable and cruise control servo bracket.
- Tighten the accelerator control cable and cruise control servo bracket nut to 10 Nm (89 inch lbs.).





18. Install the accelerator cable to the throttle lever.





19. Install the cruise control cable to the throttle lever, if equipped.





20. Install the EGR valve pipe and solenoid.
- Tighten the EGR valve pipe to exhaust manifold bolts to 30 Nm (22 ft. lbs.).
- Tighten the EGR valve pipe to cylinder head bolt to 50 Nm (37 ft. lbs.).
- Tighten the EGR valve pipe to intake manifold bolt to 10 Nm (89 inch lbs.).





21. Connect the EGR valve electrical connector.
22. Install the accessory drive belt.





23. Connect the TPS sensor electrical connector to the throttle body.
24. Connect the IAC sensor electrical connector to the throttle body.





25. Install the air intake duct to the throttle body and the air cleaner box.





26. Connect the MAF sensor electrical connector to the intake duct.
27. Connect the IAT sensor electrical connector to the intake duct.
28. Install the fuel rail.





29. Connect the fuel line to the fuel rail.
30. Connect the vapor line to the fuel vapor purge valve.
31. Raise and suitably support the vehicle. Refer to Vehicle Lifting





32. Install the transmission fluid indicator tube bolt.
- Tighten the transmission fluid indicator tube bolt to 50 Nm (37 ft. lbs.).
33. Lower the vehicle.
34. Fill the cooling system.





35. Connect the negative battery cable.