Intake manifold — removal and installation
Warning: Wait until the engine is completely cool before beginning this procedure.
Removal
1. Relieve the fuel system pressure (see Fuel and exhaust systems), then disconnect the cable from the negative battery terminal (see Engine electrical systems).
2. Remove the air intake duct and resonator (see Fuel and exhaust systems), then remove the cowl cover assembly (see Body).
2009 and earlier models
3. Remove the fuel rail and injectors as a
4. Label and detach the PCV and vacuum hoses connected to the rear of the intake manifold (see illustration).
8.4 Label and disconnect the vacuum hoses (A) and the wire harness retainers (B) from the intake manifold
5. Raise the vehicle and support it securely on jack stands. Working below the vehicle, remove the manifold lower mounting bolts (see illustration).
8.5 Intake manifold lower fastener locations
6. Working from above, remove the intake manifold upper mounting nuts and bolts. Remove the manifold, the gasket and the manifold insulator from the engine (see illustration).
8.6 Intake manifold upper fastener locations
2010 and later models
7. Remove the engine cover.
8. Disconnect the vacuum hoses and ventilation tubes from the intake manifold.
9. Remove the throttle body from the intake manifold (see Fuel and exhaust systems).
10. Disconnect the fuel inlet line to the fuel rail (see Fuel and exhaust systems). assembly. Also remove the throttle linkage and the throttle body from the intake manifold (see Fuel and exhaust systems).
11. Disconnect the electrical connectors from the fuel rail, remove the harness mounting fasteners and set the harness to the side.
12. Disconnect and remove the main harness connector to the intake manifold and tumble control valves.
Note: The tumble control valve harness connector is located just below the throttle body.
13. Using test leads, apply battery voltage to terminal no. 8 of the tumble control valve electrical connector and ground the no. 4 terminal (see illustration); this will close the tumble control valve to prevent it from being damaged when the manifold is removed. Don’t apply voltage longer than three seconds.
8.13 Tumble control valve connector pin identification — DO NOT apply voltage longer than three seconds or touch any other terminals or the actuator may be damaged.
Caution: If the voltage is applied longer than three seconds, or any other terminals are touched, the actuator may be damaged.
14. Remove the intake manifold support bracket and disconnect the vacuum switching valve assembly electrical connector.
15. Unscrew the intake manifold mounting fasteners and remove the manifold.
Installation
16. Clean the mating surfaces of the intake manifold and the cylinder head mounting surface. If the gasket shows signs of leaking, check the manifold for warpage with a straightedge and feeler gauges. If the manifold is warped, it must be replaced.
17. Press a new gasket into the grooves on the intake manifold (see illustration). Install the manifold and gasket over the studs on the cylinder head.
8.17 Press the gasket into the groove on the intake manifold
18. Tighten the manifold-to-cylinder head nuts/bolts in three or four equal steps to the torque listed in this Chapter’s Specifications. Work from the center out towards the ends to avoid warping the manifold.
19. Install the remaining parts in the reverse order of removal. Check the coolant level, adding as necessary (see Tune-up and routine maintenance).
20. Before starting the engine, check the throttle linkage for smooth operation.
21. Run the engine and check for coolant and vacuum leaks.