Removal Procedure
- Relieve the fuel system pressure. Refer to Fuel System Diagnosis.
- Disconnect the negative battery cable.
- Remove the air filter, resonator, and snorkel assembly. Refer to Air Cleaner Assembly Replacement.
- Disconnect the radiator lower hose and drain coolant (1). Refer to Radiator Replacement.
- Remove the throttle body assembly (2).
- Disconnect the positive crankcase ventilation (PCV) hose and valve. Refer to Positive Crankcase Ventilation Valve Replacement.
- Remove the fuel rail and injector (1). Refer to Fuel Injection Fuel Rail Assembly Replacement.
- Remove the exhaust gas recirculation (EGR) valve and solenoid. Refer to Exhaust Gas Recirculation Valve Replacement.
- Loosen the lock nut and disconnect the throttle cable (4).
- Disconnect the manifold absolute pressure (MAP) sensor connector (3).
- Disconnect the evaporative emission canister solenoid connector (1).
- Disconnect the brake vacuum tube (5).
- Disconnect the MAP sensor vacuum tube (2).
- Disconnect the intake air temperature (IAT) sensor connector.
- Remove the upper 2 intake manifold main bracket bolts.
- Remove the intake manifold upper bolt (1).
- Remove the intake manifold lower nut (2).
- Remove the intake manifold subsidiary bracket (3).
- Remove the intake manifold nuts (1).
- Remove the intake manifold from the cylinder head (2).
- Disconnect the intake manifold gasket from the intake manifold (2).
- Inspect the gasket for crack, hardening, inflation or damage.
Warning: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
Warning: Refer to Battery Disconnect Warning in the Preface section.
Note: Carefully remove the gasket by pulling on the upper position (1).
Installation Procedure
- Install the intake manifold gasket (2) on to manifold.
- Install the intake manifold on to the cylinder head with bracket.
- Install the intake manifold nuts in sequence order and tighten to 15-19 N·m (11-14 lb ft).
- Install the intake manifold subsidiary bracket bolt (2) and tighten to 18-22 N·m (13-16 lb ft).
- Install the intake manifold main bracket bolts.
- Connect the IAT sensor connector (6).
- Connect the MAP sensor vacuum tube (2).
- Connect the brake vacuum tube (5).
- Connect the Evaporative emission canister solenoid connector (1).
- Connect the MAP sensor connector (3).
- Connect the throttle cable (4) and tighten the lock nut.
- Install the EGR valve and solenoid. Refer to Exhaust Gas Recirculation Valve Replacement.
- Install the Injectors and fuel rail (1). Refer to Fuel Injection Fuel Rail Assembly Replacement.
- Connect the PCV hose and valve.
- Install the throttle body assembly (2).
- Connect the radiator lower hose and drain coolant (1). Refer to Radiator Replacement.
- Install the air filter, resonator, and snorkel assembly. Refer to Air Cleaner Assembly Replacement.
- Connect the negative battery cable.
Caution: Refer to Fastener Caution in the Preface section.
