Intake Manifold

REMOVAL & INSTALLATION

1.5L and 1.8L (BP) Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   • Negative battery cable
   • Mass air flow sensor electrical connector
   • Air ducts, air cleaner assembly, mass air flow sensor and resonance chamber

     Fig. 1: Exploded view of the intake manifold and related components — 1.5L engine

     Fig. 2: Exploded view of the intake manifold and related components — 1.8L (BP) engine

   • Throttle and accelerator cables
   • Fuel lines
   • Coolant hoses from the throttle body
   • Idle Air Control (IAC) valve and the Throttle Position Sensor (TPS) electrical connectors
   • Throttle body
   • Vacuum lines at the intake manifold
   • Dynamic chamber (upper intake manifold)
   • Fuel hoses from the fuel rail
   • Electrical connectors for the fuel injectors

   NOTE: On some models, it may be necessary to remove the fuel rail with the injectors connected.

5. On the 1.5L engine, remove the Exhaust Gas Recirculation (EGR) pipe from the intake manifold. Remove the EGR and PRC solenoid valve brackets.
6. Remove or disconnect the following:
   • Intake manifold support bracket
   • Intake manifold and discard the gasket

   To install:

7. Clean all gasket mating surfaces.
8. Install or connect the following:
   • Intake manifold using a new gasket. Tighten the nuts/bolts to 14–18 ft. lbs. (19–25 Nm).
   • EGR pipe to the manifold
   • Intake manifold support bracket. Tighten the bolts to 38 ft. lbs. (51 Nm).
   • EGR and PRC solenoid valve brackets, if removed
   • Fuel rail and injector assembly
   • Electrical connectors to the injectors
   • Fuel lines to the rail
   • Upper intake manifold using new gaskets. Tighten the nuts to 14–18 ft. lbs. (19–25 Nm).
   • Throttle body using a new gasket. Tighten the bolts to 14–18 ft. lbs. (19–25 Nm).
   • Electrical connectors for the IAC valve and the TPS
   • Vacuum and coolant lines
   • Connect and adjust the throttle and accelerator cables
   • Fuel lines
   • Resonance chamber
   • Air cleaner assembly, mass air flow sensor and ducts
   • Mass air flow sensor connector
   • Negative battery cable
9. Fill the cooling system.
10. Run the engine and check for leaks.

1.6L and 1.8L (FP) Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure. Drain the cooling system.
3. Remove or disconnect the following:
   • Negative battery cable
   • Fuel hoses from the fuel rail
   • Fuel injector electrical connectors
   • Fuel rail with the injectors connected
   • Components in the order illustrated

     Fig. 3: Exploded view of the intake manifold, illustrating the removal and installation components with tightening values — 1.6L engine

     Fig. 4: Exploded view of the intake manifold, illustrating the removal and installation components with tightening values — 1.8L (FP) engine

   To install:

4. Clean all gasket mating surfaces.

   NOTE: Be sure that the convex side of the intake manifold gasket is facing the manifold side, as shown.

   Fig. 5: Cross-sectional view of the intake manifold gasket — 1.6L and 1.8L engines

5. Install or connect the following:
   • Intake manifold using a new gasket. Tighten the nuts/bolts to 14–18 ft. lbs. (19–25 Nm).
   • Components in the reverse order of the removal sequence
   • Fuel rail. Tighten the bolts to 14–18 ft. lbs. (19–25 Nm).
   • Fuel lines and electrical connectors to the fuel rail
   • Negative battery cable
6. Fill the cooling system.
7. Run the engine and check for leaks.

2.3L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   • Negative battery cable
   • Dynamic chamber cover
   • Charge air cooler air duct
   • Vacuum hoses and electrical connectors from the air cleaner housing
   • Air cleaner assembly
   • Fresh air ducts

     Fig. 6: Exploded view of the intake manifold assembly (1 of 2) — 2.3L engine

     Fig. 7: Exploded view of the intake manifold assembly (2 of 2) — 2.3L engine

   • Mass air flow sensor and the air intake hose from the throttle body
   • Resonator
   • Right-hand charge air cooler
   • Left-hand charge air cooler
   • Accelerator cable
   • Vacuum hoses from the rear of the intake manifold and Exhaust Gas Recirculation (EGR) valve
   • EGR valve
   • Air intake pipe assembly
   • Charge air cooler pipe
   • Fuel supply line at the fuel rails and discard the copper washers
   • Fuel and vacuum lines from the fuel pressure regulator
   • Coolant hoses
   • Wiring harness from the intake manifold
   • Intake manifold mounting nuts and bolts in 2–3 steps
   • Intake manifold
5. If necessary, label and disconnect the fuel hoses and electrical connectors from the throttle body. Remove the throttle body.

   To install:

6. Clean all gasket mating surfaces.
7. Install or connect the following:
   • Throttle body, if removed. Tighten the nuts/bolts to 14–18 ft. lbs. (19–25 Nm).
   • Fuel hoses and electrical connectors.
   • Intake manifold using new gaskets. Tighten the nuts/bolts in 2–3 steps, from the center to the ends, to 14–18 ft. lbs. (19–25 Nm).
   • Wiring harness onto the intake manifold
   • Coolant hoses
   • Fuel and vacuum lines to the fuel pressure regulator
   • Fuel supply line to the fuel rail using new copper washers
   • Charge air cooler pipe
   • Air intake pipe assembly using new gaskets. Verify that the rubber gaskets are not twisted or distorted. Tighten the bolts marked A to 70–95 inch lbs. (8–11 Nm) and all other bolts, in sequence, to 14–18 ft. lbs. (19–25 Nm).
   • EGR valve using a new gasket
   • Vacuum hoses to the intake manifold and EGR valve
   • Accelerator cable, adjust as necessary
   • Left and right-hand charge air coolers using new gaskets. Verify that the rubber gaskets are not twisted or distorted. Tighten the bolts marked A to 44–78 inch lbs. (5–9 Nm). Tighten the bolts marked B to 70–95 inch lbs. (8–11 Nm) and all other bolts, in sequence, to 14–18 ft. lbs. (19–25 Nm).
   • Resonator. Tighten the nuts/bolts to 12–16 ft. lbs. (16–22 Nm).
   • Air intake hose onto the throttle body
   • Mass air flow sensor
   • Fresh air and air ducts
   • Air cleaner assembly
   • Vacuum hoses and electrical connectors to the air cleaner housing
   • Charge air cooler air duct. Tighten the bolts to 70–95 inch lbs. (8–11 Nm).
   • Dynamic chamber cover
   • Negative battery cable
8. Fill the cooling system.
9. Run the engine and check for leaks.

2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   • Negative battery cable

     Fig. 8: Exploded view of the intake manifold assembly — 2.5L engine

   • Air cleaner assembly and ducts
   • Accelerator cable
   • Necessary electrical connectors and vacuum hoses
   • Fuel lines
   • Coolant hose from the air bypass valve
   • Intake manifold support bracket
   • Intake manifold-to-cylinder head bolts
   • Intake manifold
   • Throttle body and air intake pipe from the manifold, if necessary
5. Check the intake manifold for cracks or other damage. Check the surface of the cylinder heads and intake manifold for warpage using a straightedge. Replace the intake manifold, as necessary.

   To install:

6. Clean all gasket mating surfaces.
7. Install or connect the following:
   • Throttle body using new gaskets, if removed. Tighten the nuts/bolts to 19 ft. lbs. (25 Nm).
   • Air intake pipe using a new O-rings lubricated with engine oil, if removed. Tighten the bolts to 95 inch lbs. (10.8 Nm).
   • Intake manifold using new gaskets. Tighten the bolts, in 2–3 steps, to 19 ft. lbs. (25 Nm), working from the center toward the ends of the manifold.
   • Intake manifold bracket. Tighten the bolts to 19 ft. lbs. (25 Nm).
   • Coolant hose to the air bypass valve
   • Fuel lines
   • Vacuum hoses and electrical connectors
   • Accelerator cable
   • Air cleaner assembly and ducts
   • Negative battery cable
8. Fill the cooling system.
9. Start the engine and check for leaks. Check the idle speed.