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Intake Manifold

Removal & Installation

2.0L Engine

To Remove:

Intake manifold removal/installation (2.0L)

  1. Relieve the fuel system pressure.
  2. Drain the coolant.
  3. Remove the air cleaner.
  4. Remove the throttle body.
  5. Remove the fuel rail and injector assembly.
  6. Remove the MAP sensor.
  7. Disconnect the cruise control vacuum hose.
  8. Remove the vacuum pipe.
  9. Disconnect the brake booster vacuum hose.
  10. Remove the vacuum pipe assembly.
  11. Remove the EGR valve.
  12. Remove the engine hanger.
  13. Remove the throttle body stay.
  14. Remove the intake manifold stay.
  15. Remove the intake manifold and gasket.

To Install:

  1. Install the intake manifold and gasket.
  2. Install the intake manifold stay.
  3. Install the throttle body stay.
  4. Install the engine hanger.
  5. Install the EGR valve.
  6. Install the vacuum pipe assembly.
  7. Connect the brake booster vacuum hose.
  8. Install the vacuum pipe.
  9. Connect the cruise control vacuum hose.
  10. Install the MAP sensor.
  11. Install the fuel rail and injector assembly.
  12. Install the throttle body.
  13. Install the air cleaner.
  14. Refill the cooling system.
2.0L Turbo Engine

To Remove:

Intake manifold removal/installation (2.0L Turbo)

  1. Relieve the fuel system pressure.
  2. Remove the under cover.
  3. Drain the coolant.
  4. Remove the intake air duct.
  5. Remove the strut brace.
  6. Remove the throttle body.
  7. Remove the crossmember bar.
  8. Remove the front exhaust pipe.
  9. Remove the center cover.
  10. Disconnect the electrical connectors from the following;
  11. Disconnect the vacuum hoses.
  12. Disconnect the fuel lines.
  13. Remove the fuel rail and injector assembly.
  14. Remove the dipstick tube.
  15. Disconnect the brake booster vacuum hose.
  16. Disconnect the EVAP purge hoses.
  17. Disconnect the connectors from the knock sensor and EVAP purge solenoid.
  18. Remove the fuel pressure solenoid.
  19. Disconnect the PCV hose.
  20. Remove the generator.
  21. Disconnect the EGR vacuum regulator solenoid and vacuum pipe assembly.
  22. Remove the intake manifold stay.
  23. Remove the EGR valve.
  24. Remove the ground connection.
  25. Remove the MAP sensor.
  26. Disconnect the crankshaft position sensor connector.
  27. Remove the generator brace stay.
  28. Remove the intake manifold.

To Install:

  1. Install the intake manifold with a new gasket.
  2. Install the generator brace stay.
  3. Connect the crankshaft position sensor connector.
  4. Install the MAP sensor.
  5. Install the ground connection.
  6. Install the EGR valve.
  7. Install the intake manifold stay.
  8. Connect the EGR vacuum regulator solenoid and vacuum pipe assembly.
  9. Install the generator.
  10. Connect the PCV hose.
  11. Install the fuel pressure solenoid.
  12. Connect the connectors to the knock sensor and EVAP purge solenoid.
  13. Connect the EVAP purge hoses.
  14. Connect the brake booster vacuum hose.
  15. Install the dipstick tube.
  16. Install the fuel rail and injector assembly.
  17. Connect the fuel lines.
  18. Connect the vacuum hoses.
  19. Connect the electrical connectors to the following;
  20. Install the center cover.
  21. Install the front exhaust pipe.
  22. Install the crossmember bar.
  23. Install the throttle body.
  24. Install the strut brace.
  25. Install the intake air duct.
  26. Install the under cover.
  27. Refill the cooling system.
  28. Check for leaks.
2.4L Engine

To Remove:

Intake manifold removal/installation (2.4L)

  1. Relieve the fuel system pressure.
  2. Drain the coolant.
  3. Remove the engine cover.
  4. Remove the air cleaner.
  5. Remove the strut brace.
  6. Remove the throttle body.
  7. Remove the fuel rail and injector assembly.
  8. Remove the EGR valve.
  9. Disconnect the brake booster vacuum hose and pipe.
  10. Remove the engine cover bracket.
  11. Disconnect the EVAP hose.
  12. Remove the MAP sensor.
  13. Disconnect the knock sensor.
  14. Disconnect the EVAP solenoid.
  15. Remove the harness clamps.
  16. Remove the knock sensor wiring clamp.
  17. Remove the engine oil dipstick tube.
  18. Disconnect the lower radiator hose connection.
  19. Disconnect he heater hose.
  20. Disconnect the connector from the coolant temperature sender.
  21. Remove the thermostat housing.
  22. Remove the MAP sensor.
  23. Remove the intake manifold stay and engine hanger.
  24. Remove the intake manifold.

To Install:

  1. Install the intake manifold with a new gasket.
  2. Install the intake manifold stay and engine hanger.
  3. Install the MAP sensor.
  4. Install the thermostat housing.
  5. Connect the connector to the coolant temperature sender.
  6. Connect he heater hose.
  7. Connect the lower radiator hose connection.
  8. Install the engine oil dipstick tube.
  9. Install the knock sensor wiring clamp.
  10. Install the harness clamps.
  11. Connect the EVAP solenoid.
  12. Connect the knock sensor.
  13. Install the MAP sensor.
  14. Connect the EVAP hose.
  15. Install the engine cover bracket.
  16. Connect the brake booster vacuum hose and pipe.
  17. Install the EGR valve.
  18. Install the fuel rail and injector assembly.
  19. Install the throttle body.
  20. Install the strut brace.
  21. Install the air cleaner.
  22. Install the engine cover.
  23. Refill the cooling system.

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