Intake Manifold Removal and Installation

Tools

• 10 mm socket and ratchet
• 12 mm socket
• 10 mm open-end wrench
• Long 6 mm Allen head socket or long 6 mm hex key
• Flat-tip screwdriver

Other Procedures Referenced

• FUEL-02 — Fuel Injector and Fuel Rail Removal and Installation
• BOLT-01 — Allen Head and Cheesehead Bolt Removal

Intake Manifold Removal

1. Disconnect the battery negative lead.
2. Disconnect spark plug wires from the spark plugs and move them clear.
3. Using FUEL-02, remove the fuel rail and injectors.
4. On normally aspirated cars, remove the air intake hose between the air flow sensor and the throttle body.
5. On turbocharged cars, remove the pipe between the intercooler outlet and the throttle body.
6. Disconnect the vacuum hose from the throttle body and the throttle position switch electrical connector.
7. Remove the oil dipstick tube to intake manifold mounting bolt.
8. On turbocharged cars, remove the oil air separator bracket to intake manifold bolts (2 × M6 Allen head bolts, near the oil filler tube).
9. Disconnect all hoses from the intake manifold.

Note: On normally aspirated cars, there are hoses underneath the intake manifold that cannot be disconnected until the manifold is lifted.

10. At the back of the intake manifold, disconnect the speed and reference sensor electrical connector mounting bracket from the intake manifold by loosening the retaining bolt and sliding the bracket off.
11. Loosen the intake manifold brace bolt. On normally aspirated cars, remove the bolt completely (located to the right of the throttle body near the brake booster hose connection). On turbocharged cars, only loosen — do not remove — the bolt (located to the left of the throttle body under the front edge of the manifold).
12. Disconnect the throttle cable.
13. If equipped, disconnect the cruise control cable from the servo unit (mounted on the firewall near the battery tray). Remove the cable clamp from the top of the intake manifold and move the cable aside.
14. Remove the eight intake manifold retaining bolts (M8 Allen head) using a 6 mm Allen head socket or hex key. A long (6") Allen head socket is recommended.

Note: Intake manifold bolts tend to bond to the cylinder head over time, making it easy to strip the bolt heads. To avoid this, use BOLT-01 procedures for "waking up" stuck Allen/cheesehead bolts before attempting removal.

15. If the intake manifold does not lift freely from the head, strike it with a rubber mallet to break it free.
16. On normally aspirated cars, lift the intake manifold and disconnect the vacuum lines underneath before fully removing.
17. Remove the intake manifold from the car.
18. If performing additional work with the manifold removed, cover the cylinder head intake ports with clean rags or duct tape.

Intake Manifold Installation

1. Remove the old intake manifold gaskets from the cylinder head and intake manifold using a scraper. Be careful not to scratch the mating surfaces.
2. Apply a small amount of grease to the intake manifold gaskets to hold them in place during installation, then install the gaskets on the cylinder head.

Note: Pay close attention to gasket orientation. On some cars, the gaskets are symmetrical in shape but must be installed in a specific orientation. On turbocharged cars, for example, the gasket for cylinder 1 is oriented differently from cylinders 2, 3, and 4. Installing the cylinder 1 gasket in the wrong orientation will partially block the injector flow path and affect spray pattern.

3. Set the manifold into position on the cylinder head. On normally aspirated cars, attach the vacuum hoses underneath as the manifold is lowered into place.
4. Align the intake manifold with the intake manifold brace. On turbocharged cars, the manifold is installed with the brace bolt already threaded in — slide the bolt into the "U" of the brace as the manifold descends. Torque the brace bolt (M8) to 20 Nm (15 ft-lb).
5. Install the eight intake manifold retaining bolts (M8 Allen head) and torque to 20 Nm (15 ft-lb).
6. Connect the fuel supply and return lines.
7. Connect the vacuum line connections to the fuel damper and fuel pressure regulator.
8. If equipped, connect the cruise control cable to the servo.
9. Connect the throttle cable to the throttle body.
10. Connect the vacuum line to the throttle body and the electrical connector to the throttle position switch.
11. Connect the speed and reference sensor mounting bracket at the back of the intake manifold.
12. Connect all vacuum hoses to the intake manifold.
13. Install the oil dipstick tube to intake manifold mounting bolt.
14. On turbocharged cars, install the pipe between the intercooler outlet and the throttle body.
15. On normally aspirated cars, install the air intake hose between the air flow sensor and the throttle body.
16. Using FUEL-02, install the fuel rail and injectors. Route and connect spark plug wires as the fuel rail is installed. Check for leaks as described in FUEL-02.