Intake Manifold

Removal & Installation

CAUTION
Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces

2.4L Engine

To Remove:

1. Drain the engine coolant.
2. Remove the air cleaner.
3. Remove the throttle body.
4. Remove the thermostat case assembly.
5. Disconnect the purge hose.
6. Disconnect the brake booster vacuum hose.
7. Disconnect the ignition coil.
8. Disconnect the injector.
9. Disconnect the manifold absolute pressure sensor.
10. Disconnect the evaporative emission purge solenoid valve.
11. Disconnect the EGR vacuum regulator solenoid valve.
12. Disconnect the fuel high-pressure hose.
13. Disconnect the fuel return hose.
14. Remove the oil dipstick and dipstick guide.
15. Disconnect the pressure hose.
16. Remove the PCV hose.
17. Remove the fuel return pipe.
18. Remove the fuel hose.

    CAUTION
    Be very careful that when you remove the fuel rail, you do not drop the injector.

19. When removing the fuel rail and the injector and fuel pressure regulator, remove the fuel rail with the injectors and pressure regulator attached to it.
20. Remove the insulator.
21. Remove the vacuum pipe.
22. Remove the EGR valve.
23. Remove the intake manifold and gasket.
24. Remove the intake manifold stay.
25. Remove the manifold absolute pressure sensor.
26. Remove the vacuum pipe.
27. Remove the evaporative emission purge solenoid valve.
28. Remove the EGR vacuum regulator solenoid valve and vacuum control valve.
29. Remove the accelerator cable clamp.

To Install:

1. Install the accelerator cable clamp.
2. Install the EGR vacuum regulator solenoid valve and vacuum control valve.
3. Install the evaporative emission purge solenoid valve.
4. Install the vacuum pipe.
5. Install the manifold absolute pressure sensor.
6. Install the intake manifold stay.
7. Install the intake manifold gasket and intake manifold.
8. Install the EGR valve.
9. Install the vacuum pipe.
10. Install the insulator.
11. Install the fuel rail and the injector and fuel pressure regulator.
12. Install the fuel hose.
13. Install the fuel return pipe.
14. Install the PCV hose.
15. Connect the pressure hose.
16. Install the oil dipstick and dipstick guide.
17. Connect the fuel return hose.

    CAUTION
    Use care to not let any engine oil get into the fuel rail.

18. When connecting the fuel high-pressure hose onto the fuel rail, do the following:
    • Step 1: Put a small amount of clean engine oil onto the O-ring and then insert the fuel high-pressure hose.
    • Step 2: While turning the fuel high-pressure hose to the left and right, install it onto the fuel rail.
    • Step 3: Make sure the injector turns smoothly. If it does not, it may mean the O-ring is trapped. Remove the fuel high-pressure hose then insert it into the fuel rail again. Examine it once more.
19. Connect the EGR vacuum regulator solenoid valve.
20. Connect the evaporative emission purge solenoid valve.
21. Connect the manifold absolute pressure sensor.
22. Connect the injector.
23. Connect the ignition coil.
24. Connect the brake booster vacuum hose.
25. Connect the purge hose.
26. Install the thermostat case assembly.
27. Install the throttle body.
28. Install the air cleaner.
29. Fill the engine coolant.

3.0L Engine

To Remove:

1. Remove the intake manifold plenum.
2. Disconnect the injector.
3. Disconnect the fuel high-pressure hose.
4. Remove the O-ring.
5. Disconnect the fuel return hose.
6. Disconnect the vacuum hose.

   CAUTION
   Be very careful that when you remove the fuel rail, you do not drop the injector.

7. When removing the fuel rail and the injector and fuel pressure regulator, remove the fuel rail with the injectors and pressure regulator attached to it.
8. Remove the insulators.
9. Disconnect the PCV hose.
10. Remove the timing belt front upper cover (right).
11. Remove the bracket.
12. Remove the intake manifold and gasket.

To Install:

1. Install the intake manifold gasket with the protrusions in the position as shown.

   Intake manifold gasket installation

2. To install the intake manifold, do the following:
   • Step 1: Coat the intake manifold mounting studs with clean engine oil.

     Intake manifold mounting studs

   • Step 2: Tighten the intake manifold mounting nuts by doing the following:
   • Order: 1st – right-bank nuts – 56 in-lbs (6.4 Nm)
   • Order: 2nd – left-bank nuts – 16 ft-lbs (22 Nm)
   • Order: 3rd – right-bank nuts – 16 ft-lbs (22 Nm)
   • Order: 4th – left-bank nuts – 16 ft-lbs (22 Nm)
   • Order: 5th – right-bank nuts – 16 ft-lbs (22 Nm)
3. Install the bracket.
4. Install the timing belt front upper cover on the right side.
5. Connect the PCV hose connection.
6. Install the insulators.
7. Install the fuel rail and the injector and fuel pressure regulator.
8. Connect the vacuum hose.
9. Connect the fuel return hose.
10. Install the O-ring.

    CAUTION
    Use caution and do not let any engine oil get into the fuel rail.

11. To connect the fuel high-pressure hose, do the following:
    • Step 1: When connecting the fuel high-pressure hose to the fuel rail, put a little bit of clean engine oil onto the O-ring and then insert the fuel high-pressure hose. Be very careful not to damage the O-ring.
    • Step 2: While rotating the fuel high-pressure hose to the left and right, install it to the fuel rail.
    • Step 3: Make sure the injector rotates smoothly. If it does not, the O-ring may be caught. Remove the fuel high-pressure hose and then insert it into the fuel rail again and examine it.
12. Connect the injector.