Isuzu_Rodeo_Rodeo_Sport_1997-2004

Intake Manifold

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following: Negative battery cableAccessory drive beltPositive Crankcase Ventilation (PCV) valve and hoseAir intake ductThrottle body water hosesThrottle Position (TP) sensor connectorIdle Air Control (IAC) valve connectorFuel linesFuel injector connectorsFuel pressure regulator vacuum lineFuel supply manifoldAccelerator cableAlternator and bracketsWater pipeIntake manifold bracketIgnition coil and bracketBrake booster vacuum lineIntake manifold

    Negative battery cable
     
    Accessory drive belt
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Air intake duct
     
    Throttle body water hoses
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Fuel lines
     
    Fuel injector connectors
     
    Fuel pressure regulator vacuum line
     
    Fuel supply manifold
     
    Accelerator cable
     
    Alternator and brackets
     
    Water pipe
     
    Intake manifold bracket
     
    Ignition coil and bracket
     
    Brake booster vacuum line
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following: Intake manifold. Use a new gasket and tighten the bolts to 16 ft. lbs. (22 Nm).Brake booster vacuum lineIgnition coil and bracketIntake manifold bracket. Tighten the bolts to 16 ft. lbs. (22 Nm).Water pipeAlternator and brackets. Tighten the short bolts to 14 ft. lbs. (20 Nm) and the long bolts to 25 ft. lbs. (35 Nm).Accelerator cableFuel supply manifoldFuel pressure regulator vacuum lineFuel injector connectorsFuel linesIAC valve connectorTP sensor connectorThrottle body water hosesAir intake ductPCV valve and hoseAccessory drive beltNegative battery cable

    Intake manifold. Use a new gasket and tighten the bolts to 16 ft. lbs. (22 Nm).
     
    Brake booster vacuum line
     
    Ignition coil and bracket
     
    Intake manifold bracket. Tighten the bolts to 16 ft. lbs. (22 Nm).
     
    Water pipe
     
    Alternator and brackets. Tighten the short bolts to 14 ft. lbs. (20 Nm) and the long bolts to 25 ft. lbs. (35 Nm).
     
    Accelerator cable
     
    Fuel supply manifold
     
    Fuel pressure regulator vacuum line
     
    Fuel injector connectors
     
    Fuel lines
     
    IAC valve connector
     
    TP sensor connector
     
    Throttle body water hoses
     
    Air intake duct
     
    PCV valve and hose
     
    Accessory drive belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Air intake duct
     
    Throttle body water hoses
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Fuel lines
     
    Fuel injector connectors
     
    Fuel pressure regulator vacuum line
     
    Fuel supply manifold
     
    Accelerator cable
     
    Alternator and brackets
     
    Water pipe
     
    Intake manifold bracket
     
    Ignition coil and bracket
     
    Brake booster vacuum line
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold. Use a new gasket and tighten the bolts to 16 ft. lbs. (22 Nm).
     
    Brake booster vacuum line
     
    Ignition coil and bracket
     
    Intake manifold bracket. Tighten the bolts to 16 ft. lbs. (22 Nm).
     
    Water pipe
     
    Alternator and brackets. Tighten the short bolts to 14 ft. lbs. (20 Nm) and the long bolts to 25 ft. lbs. (35 Nm).
     
    Accelerator cable
     
    Fuel supply manifold
     
    Fuel pressure regulator vacuum line
     
    Fuel injector connectors
     
    Fuel lines
     
    IAC valve connector
     
    TP sensor connector
     
    Throttle body water hoses
     
    Air intake duct
     
    PCV valve and hose
     
    Accessory drive belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

3.2L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following: Negative battery cableEngine coverAir cleaner assemblyAccelerator cableCruise control cableBrake booster vacuum lineManifold Absolute Pressure (MAP) sensor connectorIdle Air Control (IAC) valve connectorThrottle Position (TP) sensor connectorCanister purge solenoid connectorElectronic Vacuum Sensing Valve (EVSV) connector and vacuum lineExhaust Gas Recirculation (EGR) valvePositive Crankcase Ventilation (PCV) valve and hosePressure regulator vacuum lineVentilation hoseThrottle bodyFuel linesFuel injector connectorsIntake manifold

    Negative battery cable
     
    Engine cover
     
    Air cleaner assembly
     
    Accelerator cable
     
    Cruise control cable
     
    Brake booster vacuum line
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Canister purge solenoid connector
     
    Electronic Vacuum Sensing Valve (EVSV) connector and vacuum line
     
    Exhaust Gas Recirculation (EGR) valve
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Pressure regulator vacuum line
     
    Ventilation hose
     
    Throttle body
     
    Fuel lines
     
    Fuel injector connectors
     
    Intake manifold
     

  4.  

To install:

  1. Install or connect the following: Intake manifold. Tighten the fasteners to 18 ft. lbs. (25 Nm).Fuel injector connectorsFuel linesThrottle body. Tighten the bolts to 88 inch lbs. (10 Nm).Ventilation hosePressure regulator vacuum linePCV valve and hoseEGR valveEVSV connector and vacuum lineCanister purge solenoid connectorTP sensor connectorIAC valve connectorMAP sensor connectorBrake booster vacuum lineCruise control cableAccelerator cableAir cleaner assemblyEngine coverNegative battery cable

    Intake manifold. Tighten the fasteners to 18 ft. lbs. (25 Nm).
     
    Fuel injector connectors
     
    Fuel lines
     
    Throttle body. Tighten the bolts to 88 inch lbs. (10 Nm).
     
    Ventilation hose
     
    Pressure regulator vacuum line
     
    PCV valve and hose
     
    EGR valve
     
    EVSV connector and vacuum line
     
    Canister purge solenoid connector
     
    TP sensor connector
     
    IAC valve connector
     
    MAP sensor connector
     
    Brake booster vacuum line
     
    Cruise control cable
     
    Accelerator cable
     
    Air cleaner assembly
     
    Engine cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for proper operation.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Air cleaner assembly
     
    Accelerator cable
     
    Cruise control cable
     
    Brake booster vacuum line
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Canister purge solenoid connector
     
    Electronic Vacuum Sensing Valve (EVSV) connector and vacuum line
     
    Exhaust Gas Recirculation (EGR) valve
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Pressure regulator vacuum line
     
    Ventilation hose
     
    Throttle body
     
    Fuel lines
     
    Fuel injector connectors
     
    Intake manifold

    Click image to see an enlarged view

    Fig. Intake manifold (common chamber)-3.2L engines

     

  4.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the fasteners to 18 ft. lbs. (25 Nm).
     
    Fuel injector connectors
     
    Fuel lines
     
    Throttle body. Tighten the bolts to 88 inch lbs. (10 Nm).
     
    Ventilation hose
     
    Pressure regulator vacuum line
     
    PCV valve and hose
     
    EGR valve
     
    EVSV connector and vacuum line
     
    Canister purge solenoid connector
     
    TP sensor connector
     
    IAC valve connector
     
    MAP sensor connector
     
    Brake booster vacuum line
     
    Cruise control cable
     
    Accelerator cable
     
    Air cleaner assembly
     
    Engine cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for proper operation.
  4.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery ground.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Tag and disconnect all wiring and hoses from the intake manifold.
  8.  
  9. Remove the throttle body.
  10.  
  11. Remove the bolts and nuts and lift off the manifold.
  12.  
  13. Installation is the reverse of removal. Use new gaskets. Torque the intake manifold nuts and bolts to 13 ft. lbs. (18 Nm). Torque the throttle body bolts to 87 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold-3.5L engines

  14.  

3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following: Negative battery cableEngine coverAir cleaner assemblyAccelerator cableCruise control cableBrake booster vacuum lineManifold Absolute Pressure (MAP) sensor connectorIdle Air Control (IAC) valve connectorThrottle Position (TP) sensor connectorCanister purge solenoid connectorElectronic Vacuum Sensing Valve (EVSV) connector and vacuum lineExhaust Gas Recirculation (EGR) valvePositive Crankcase Ventilation (PCV) valve and hosePressure regulator vacuum lineVentilation hoseThrottle bodyFuel linesFuel injector connectorsIntake manifold

    Negative battery cable
     
    Engine cover
     
    Air cleaner assembly
     
    Accelerator cable
     
    Cruise control cable
     
    Brake booster vacuum line
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Canister purge solenoid connector
     
    Electronic Vacuum Sensing Valve (EVSV) connector and vacuum line
     
    Exhaust Gas Recirculation (EGR) valve
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Pressure regulator vacuum line
     
    Ventilation hose
     
    Throttle body
     
    Fuel lines
     
    Fuel injector connectors
     
    Intake manifold
     

  4.  

To install:

  1. Install or connect the following: Intake manifold. Tighten the fasteners to 18 ft. lbs. (25 Nm).Fuel injector connectorsFuel linesThrottle body. Tighten the bolts to 88 inch lbs. (10 Nm).Ventilation hosePressure regulator vacuum linePCV valve and hoseEGR valveEVSV connector and vacuum lineCanister purge solenoid connectorTP sensor connectorIAC valve connectorMAP sensor connectorBrake booster vacuum lineCruise control cableAccelerator cableAir cleaner assemblyEngine coverNegative battery cable

    Intake manifold. Tighten the fasteners to 18 ft. lbs. (25 Nm).
     
    Fuel injector connectors
     
    Fuel lines
     
    Throttle body. Tighten the bolts to 88 inch lbs. (10 Nm).
     
    Ventilation hose
     
    Pressure regulator vacuum line
     
    PCV valve and hose
     
    EGR valve
     
    EVSV connector and vacuum line
     
    Canister purge solenoid connector
     
    TP sensor connector
     
    IAC valve connector
     
    MAP sensor connector
     
    Brake booster vacuum line
     
    Cruise control cable
     
    Accelerator cable
     
    Air cleaner assembly
     
    Engine cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for proper operation.
  4.  

 
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