Contents: Removal ↓ Installation ↓
Removal
Remove the intake manifold on a cold engine in the following order:
- turn off the ignition and disconnect the ground wire from the battery;
- loosen the clamp securing the air duct to the throttle body, release the four spring clips and remove the air filter cover, resonator and air duct;
- disconnect the cooling system hoses from the throttle body and plug them to prevent coolant leakage;
- remove the exhaust gas recirculation valve and the modulator vacuum valve from the intake manifold;
Figure 3.4. Location of ground wire mounting bolts on the intake manifold heat shield side
- mark and disconnect the wires and hoses from the intake manifold and throttle body. Remove the 2 ground wire mounting bolts from the intake manifold heat shield side and disconnect the connector from the knock sensor (figure 3.4);
Figure 3.5. Location of intake manifold bracket mounting bolts
- disconnect the electrical connectors from the ignition coils, unscrew the bolts and remove the intake manifold bracket (figure 3.5) and ignition coils (figure 3.6);
Figure 3.6. Location of ignition coil mounting bolts
- bend the plates that secure the heads of the intake manifold mounting bolts from unscrewing;
Figure 3.7. Location of intake manifold mounting bolts
- unscrew the bolts and nuts and remove the intake manifold from the engine (figure 3.7).
Installation
Perform installation in the following order:
- use a scraper to remove any remaining old gasket and sealant from the mating surfaces of the intake manifold and cylinder head, then clean the surfaces with solvent;
- install the intake manifold with a new gasket onto the engine and secure with bolts and nuts. Tighten the bolts and nuts in several passes, starting from the center and then in a spiral, to avoid deforming the intake manifold.
Further installation is carried out in the reverse order of removal, taking into account the following.
Check all throttle body connections and smooth throttle movement.
Check the coolant level and top it up if necessary.
Start the engine and check for coolant leaks.
Road test the vehicle and check the operation of all systems, including the cruise control system.