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Intake Manifold Replacement

Intake Manifold Replacement

Removal Procedure


1. Turn the ignition OFF.

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

3. Remove the charge air cooler outlet air hose from throttle body adapter. Refer to Charge Air Cooler Outlet Hose Replacement (Diesel) Charge Air Cooler Outlet Hose Replacement (LAU/A28NER) Charge Air Cooler Outlet Hose Replacement (LLU/A16LET) .

4. Remove the 3 connectors from the wiring harness from the intake air manifold.

5. Remove the fastener of the bracket from the wiring harness and put the cable canal aside.

6. Relief the fuel pressure. Refer to Fuel Pressure Relief .

7. Remove the brake booster vacuum pipe from the intake manifold.

8. Remove the evaporative emission canister purge solenoid valve from the intake manifold. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (LLU/A16LET) .

9.
Note

Secure both fuel pipes with a cable tie.


Remove the fuel feed pipe and the fuel return pipe from the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .

10. Remove vacuum hose from the intake manifold.

11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

12. Remove the 4 fasteners of the bracket from the charge air bypass valve vacuum tank. Refer to Charge Air Bypass Valve Vacuum Tank Replacement .

13. Lower the vehicle.

14. Remove the intake manifold (3) from the cylinder head (5).


15. Remove the 8 fasteners (1, 2) of the intake manifold.

16. Remove the gasket (4) of the intake manifold.


Manifold Disassemble


1. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement .

2. Remove the positive crankshaft ventilation pipe.

3. Remove the fuel injector wiring harness.

4. Remove the 3 brackets and the 4 fasteners.

5. Remove the 2 fasteners (2) of the multiport fuel injection fuel rail (3) from the intake manifold (1).


6. Remove the threaded connector.


Manifold Assemble


1. Install the threaded connector.

2. Install the 2 fasteners (2) of the multiport fuel injection fuel rail (3) to the intake manifold (1).


3. Install the 3 brackets and the 4 fasteners.

4. Install the fuel injector wiring harness.

5. Install the positive crankshaft ventilation pipe.

6. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement .


Installation Procedure


1. Clean the sealing surfaces.

2. Install a NEW intake manifold gasket.


3. Refer to Fastener Caution .

Install the intake manifold (3) to the cylinder head (5).

4. Install the 8 fasteners (1, 2) for the intake manifold and tighten to 20 Nm (15 lb ft) .

5. Raise the vehicle.

6. Install the 4 fasteners of the bracket to the charge air bypass valve vacuum tank. Refer to Charge Air Bypass Valve Vacuum Tank Replacement .

7. Lower the vehicle.

8. Install vacuum hose to the intake manifold.

9. Install the fuel feed pipe and the fuel return pipe to the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .

10. Install the evaporative emission canister purge solenoid valve to the intake manifold. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (LLU/A16LET) .

11. Install the brake booster vacuum pipe to the intake manifold.

12. Install the fastener of the bracket of the wiring harness and place the cable canal.

13. Install the 3 connectors of the wiring harness to the intake air manifold.

14. Install the charge air cooler outlet air hose to the throttle body adapter. Refer to Charge Air Cooler Outlet Hose Replacement (Diesel) Charge Air Cooler Outlet Hose Replacement (LAU/A28NER) Charge Air Cooler Outlet Hose Replacement (LLU/A16LET) .

15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .