Intake Manifold Removal and Installation (Without ETCS)

Intake Manifold Removal and Installation

Exploded View

5 x 0.8 mm
6 N·m (0.6 kgf·m,
4 lbf·ft)INTAKE MANIFOLD
Replace if cracked or if
mating surface is damaged.O-RING
Replace.GASKET
Replace.THROTTLE BODYEXHAUST GAS
RECIRCULATION
(EGR) PLATEINTAKE MANIFOLD
BRACKET A8 x 1.25 mm
22 N·m
(2.2 kgf·m,
16 lbf·ft)O-RINGS
Replace.6 x 1.0 mm
12 N·m (1.2 kgf·m,
8.7 lbf·ft)BOOST PLATEMANIFOLD ABSOLUTE
PRESSURE (MAP) SENSOR5 x 0.8 mm
3.4 N·m (0.35 kgf·m,
2.5 lbf·ft)O-RINGS
Replace.6 x 1.0 mm
12 N·m (1.2 kgf·m,
8.7 lbf·ft)6 x 1.0 mm
12 N·m (1.2 kgf·m,
8.7 lbf·ft)

Removal:

1.	Remove the intake manifold cover.

2.	Remove the air cleaner housing.

3.	Remove the breather hose (A), brake booster vacuum hose (B) and Positive Crankcase Ventilation (PCV) hose (C). CBA

4.	Remove the throttle cable.

5.	Remove the harness holder (A) and water bypass hose clamp (B). BA

6.	Remove the Evaporative Emission (EVAP) canister hose. When Moving the Intake Manifold: When Replacing the Intake Manifold:

7.	When replacing the intake manifold, remove the throttle body.

8.	If the engine coolant was drained, remove the water bypass hoses.

9.	Remove the engine wire harness connectors and wire harness clamps from the intake manifold. Idle Air Control (IAC) valve connector Throttle Position (TP) sensor connector Manifold Absolute Pressure (MAP) sensor connector Evaporative Emission (EVAP) canister purge valve connector

10.	Remove the intake manifold bracket A (A), then remove the intake manifold (B) and Exhaust Gas Recirculation (EGR) plate (C). BCA

Installation:

1.	Install the Exhaust Gas Recirculation (EGR) plate (A) with a new gasket (B). CAEBG 6 x 1.0 mm 12 N·m (1.2 kgf·m, 8.7 lbf·ft)F 6 x 1.0 mm 12 N·m (1.2 kgf·m, 8.7 lbf·ft)D8 x 1.25 mm 22 N·m (2.2 kgf·m, 16 lbf·ft)

2.	Install the intake manifold (C) and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. Using the new O-rings (D).

3.	Loosely install the intake manifold bracket A (E), and tighten the bolt (F) first, then the bolt (G).

4.	Install the water bypass hoses, if it was removed.

5.	Install the throttle body (A) with a new O-ring (B), if it was removed. 6 x 1.0 mm 12 N·m (1.2 kgf·m, 8.7 lbf·ft)BA

6.	Install the Evaporative Emission (EVAP) canister hose. If Intake Manifold was Moved: If Intake Manifold was Replaced:

7.	Install the harness holder (A) and water bypass hose clamp (B). BA6 x 1.0 mm 12 N·m (1.2 kgf·m, 8.7 lbf·ft)6 x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)6 x 1.0 mm 12 N·m (1.2 kgf·m, 8.7 lbf·ft)

8.	Install the throttle cable, then adjust it.

9.	Install the breather hose (A), brake booster vacuum hose (B) and Positive Crankcase Ventilation (PCV) hose (C). CBA

10.	Install the air cleaner housing.

11.	Install the intake manifold cover.

12.	After installation, check that all tubes, hoses and connectors are installed correctly.

13.	If engine coolant drained, refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.