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. Refer to Throttle Body Assembly Replacement .
2. Remove the fuel injectors. Refer to Fuel Injector Replacement .
   
   
   
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. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold.
   
   
   
7. Remove the positive crankcase ventilation (PCV) hose.
   
   
   
8. Remove the MAP sensor (1) from the intake manifold.
   
   
   
9. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:

   9.1.	Remove the EVAP tube end from the solenoid (1).

   9.2.	Remove the EVAP tube end from the vapor pipe (2).

   
   
   
   
10. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold.
    
    
    
11. Loosen the intake manifold bolts.
12. Remove the intake manifold.
    
    
13. Remove the intake manifold gaskets (1) from the intake manifold.
14. Discard the old intake manifold gaskets.
15. If required, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection .

1. Install NEW intake manifold gaskets (1) to the intake manifold.
   
   
   
2. Install the intake manifold.
3. Apply a 5 mm (0.2 in) band of threadlocker to the threads of the intake manifold bolts. Refer to Sealers, Adhesives, and Lubricants for the correct part number.

   Notice: Refer to Fastener Notice in the Preface section.

   
   
   
   
4. Tighten the intake manifold bolts.

   Tighten

   •	Tighten the bolts a first pass in sequence to 5 N·m (44 lb in).

   •	Tighten the 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
   Tighten the bolt to 10 N·m (89 lb in).

   
   
   
   
6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2).
   
   
   

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

7. Install the MAP sensor (1) to the intake manifold.
   
   
   
8. Install the PCV hose.
   
   
   
9. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold.
10. Route the electrical harness into position over the engine.
    
    
    
11. Connect the knock sensor harness electrical connector to the intake manifold.
12. Connect the following electrical connectors.

    •	MAP sensor (1)

    •	Knock sensor (2)

13. Install the fuel injectors. Refer to Fuel Injector Replacement .
14. Install the throttle body. Refer to Throttle Body Assembly Replacement .
15. Knock Sensor Replacement

    Removal Procedure

    
    
    
    
    1. Remove the intake manifold. Refer to Intake Manifold Replacement .
    2. Gently pry up the rubber covers.
    3. Disconnect the knock sensor electrical connectors.
       
       
       
    4. Remove the knock sensors.

    Installation Procedure

    
    
    
    

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    1. Install the knock sensors.

       Tighten
       Tighten the sensor to 20 N·m (15 lb ft).

       
       
       
       
    2. Connect the knock sensor electrical connectors.
    3. Push down on the rubber covers.
    4. Install the intake manifold. Refer to Intake Manifold Replacement .