Intake Manifold

Removal & Installation

2.4L Engine

To Remove:

1. Relieve the fuel system pressure.
2. Drain the engine coolant.
3. Remove the air cleaner cover and duct.
4. Remove the throttle body.
5. Remove the fuel rail assembly.
6. Remove the EGR valve.
7. Disconnect the brake booster vacuum hose and pipe.
8. Disconnect the EVAP vacuum hose.
9. Disconnect the MAP sensor connector.
10. Remove the knock sensor connector bracket.
11. Remove the engine oil dipstick and tube.
12. Disconnect the lower radiator hose.
13. Disconnect the heater water hose.
14. Remove the thermostat case.
15. Remove the MAP sensor.
16. Remove the intake manifold stay.
17. Remove the intake manifold and gasket.

To Install:

1. Install the intake manifold with a new gasket.
2. Install the intake manifold stay.
3. Install the MAP sensor.
4. Install the thermostat case.
5. Connect the heater water hose.
6. Connect the lower radiator hose.
7. Install the engine oil dipstick and tube.
8. Install the knock sensor connector bracket.
9. Connect the MAP sensor connector.
10. Connect the EVAP vacuum hose.
11. Connect the brake booster vacuum hose and pipe.
12. Install the EGR valve.
13. Install the fuel rail assembly.
14. Install the throttle body.
15. Install the air cleaner cover and duct.
16. Refill the cooling system.

3.8L Engine

To Remove:

1. Relieve the fuel system pressure.
2. Remove the intake plenum.
3. Disconnect the fuel injector connectors.
4. Remove the engine mount stay.
5. Disconnect the high pressure hose from the fuel rail.
6. Disconnect the blow by hose.
7. Remove the fuel rail assembly and insulators.
8. Disconnect the PCV hose.
9. Remove the timing belt front upper covers.
10. Remove the water pump bracket.
11. Remove the intake manifold and gasket.

To Install:

1. Install the intake manifold with new gaskets.
2. Tighten the intake manifold nuts using the following steps;
   • Tighten right nuts to 57 in-lbs (6.4 Nm)
   • Tighten left nuts to 17 ft-lbs (23 Nm)
   • Tighten right nuts to 17 ft-lbs (23 Nm)
   • Tighten left nuts to 17 ft-lbs (23 Nm)
   • Tighten right nuts to 17 ft-lbs (23 Nm)
3. Install the water pump bracket.
4. Install the timing belt front upper covers.
5. Connect the PCV hose.
6. Install the fuel rail assembly and insulators.
7. Connect the blow by hose.
8. Connect the high pressure hose to the fuel rail.
9. Install the engine mount stay.
10. Connect the fuel injector connectors.
11. Install the intake plenum.
12. Inspect the fuel connection for leakage.