Subaru Car 1998-05

Intake Manifold

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Removal & Installation



1.8L Engine


Click image to see an enlarged view

Fig. Intake manifold assembly-1.8L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Disconnect the fuel lines.
  8.  
  9. Drain the cooling system into a suitable container. Remove the radiator hoses.
  10.  
  11. On turbocharged models, remove the air duct with the airflow meter attached. On all other models, remove the air duct.
  12.  
  13. On turbocharged models, remove the turbo cooling hose and turbocharger.
  14.  
  15. Remove the front exhaust pipe from the cylinder head as required.
  16.  
  17. Tag and disconnect the distributor high tension wires, then matchmark and remove the distributor.
  18.  
  19. Label and disconnect all applicable vacuum hoses.
  20.  
  21. Remove the alternator, if needed for additional working space.
  22.  
  23. Remove the silencers and silencer hoses. Remove the air cleaner assembly.
  24.  
  25. Remove the air suction valves and hoses.
  26.  
  27. Remove the EGR cover and EGR pipe.
  28.  
  29. Remove the PCV valve and blow-by hoses.
  30.  
  31. Label and disconnect all applicable electrical harnesses.
  32.  
  33. Disconnect the accelerator cable.
  34.  
  35. Remove the intake manifold bolts and carefully lift the intake manifold off the engine.
  36.  
  37. Clean all gasket material from the mating surfaces.
  38.  
  39. Installation is the reverse of removal. Tighten all components to specifications.
  40.  
  41. Use a straightedge feeler gauge to inspect the intake manifold for flatness. Distortion should not exceed 0.020 inch (0.5mm).
  42.  
  43. Install the intake manifold using new gaskets, and secure in place with the mounting bolts. Tighten the bolts to 13-16 ft. lbs. (18-22 Nm).
  44.  
  45. Inspect all electrical connectors for damage and replace as necessary. Attach all electrical connectors.
  46.  
  47. Tighen the EGR cover and pipe bolts to 23-27 ft. lbs. (31-37 Nm).
  48.  
  49. Inspect all vacuum lines for damage and replace as necessary.
  50.  
  51. On turbocharged models, install the turbo cooling hose and turbocharger and the air duct with the airflow meter.
  52.  
  53. Install the radiator hose and fill the cooling system.
  54.  
  55. Connect the negative battery cable, start the engine and allow it to reach operating temperature. Check for leaks. Test drive the vehicle.
  56.  

2.0L Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly-2.0L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if necessary
     
    Air cleaner upper cover and boot
     
    Air cleaner filter
     
    Intercooler
     
    Accelerator cable
     
    Coolant filler tank
     

  6.  
  7. Remove the power steering pump from the bracket by performing the following steps:
    1. Loosen the lock and slider bolts.
    2.  
    3. Remove the V-belt.
    4.  
    5. Disconnect the power steering switch connection.
    6.  
    7. Remove the bolts that attach the power steering pump pipe brackets to the intake manifold. Do not disconnect the hose.
    8.  
    9. Bolts that attach the power steering pump bracket.
    10.  
    11. Remove the power steering tank from the bracket by pulling it upwards.
    12.  
    13. Place the power steering pump on the wheel apron on the right.
    14.  

  8.  
  9. Remove or disconnect the following:

    Emission hose from the Positive Crankcase Ventilation (PCV) valve
     
    Engine coolant temperature hoses from the throttle body
     
    Brake booster hose
     
    Pressure hose from the intake duct
     
    Engine harness connectors from the bulkhead connections
     

  10.  
  11. Disconnect the following electrical connections:

    Engine Coolant Temperature (ECT) sensor
     
    Oil pressure switch
     
    Crankshaft Position (CKP) sensor
     
    Knock Sensor (KS)
     
    Camshaft Position (CMP) sensor
     
    Ignition coil
     

  12.  
  13. Remove or disconnect the following:

    Engine harness fixed clip from the bracket
     
    Fuel delivery, return and evaporative hoses
     
    Intake manifold bolts
     
    Intake manifold and gasket
     

  14.  

To install:



Click image to see an enlarged view

Fig. Location of the intake manifold bolts-2.0L engine

  1. Install or connect the following:

    Intake manifold and gasket
     
    Intake manifold bolts and tighten to 18 ft. lbs. (25 Nm)
     
    Fuel delivery, return and evaporative hoses
     
    Engine harness fixed clip from the bracket
     

  2.  
  3. Connect the following electrical connections:

    Oil pressure switch
     
    CKP sensor
     
    ECT sensor
     
    KS sensor
     
    CMP sensor
     
    Ignition coil
     
    Engine harness connectors to the bulkhead connections
     

  4.  
  5. Install or connect the following:

    Brake booster hose
     
    Engine coolant temperature hoses to the throttle body
     
    Emission hose to the PCV valve
     
    Pressure hose to the intake duct
     

  6.  
  7. Install the power steering pump on the bracket by performing the following steps:
    1. Install the power steering tank on the bracket.
    2.  
    3. Attach the power steering switch connection.
    4.  
    5. Install the bolts that attach the power steering pump bracket and tighten to 16 ft. lbs. (22 Nm).
    6.  
    7. Attach the power steering pump pipe brackets to the intake manifold.
    8.  
    9. Install the V-belt.
    10.  

  8.  
  9. Install or connect the following:

    Coolant filler tank
     
    Accelerator cable
     
    Intercooler
     
    Air cleaner filter
     
    Air cleaner upper cover and boot
     
    Engine undercover
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine and allow it to reach operating temperature. Check for leaks and test drive the vehicle.
  14.  



Click image to see an enlarged view

Fig. Intake manifold and related components-2.0L engine

  1. Release the fuel system pressure.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if necessary
     
    Air cleaner upper cover and boot
     
    Air cleaner filter
     
    Intercooler
     
    Accelerator cable
     
    Coolant filler tank
     

  4.  
  5. Remove the power steering pump from the bracket by performing the following steps:
    1. Loosen the lock and slider bolts.
    2.  
    3. Remove the V-belt.
    4.  
    5. Disconnect the power steering switch connection.
    6.  
    7. Remove the bolts that attach the power steering pump pipe brackets to the intake manifold. Do not disconnect the hose.
    8.  
    9. Bolts that attach the power steering pump bracket.
    10.  
    11. Remove the power steering tank from the bracket by pulling it upwards.
    12.  
    13. Place the power steering pump on the wheel apron on the right.
    14.  

  6.  
  7. Remove or disconnect the following:

    Emission hose from the Positive Crankcase Ventilation (PCV) valve
     
    Engine coolant temperature hoses from the throttle body
     
    Brake booster hose
     
    Pressure hose from the intake duct
     
    Engine harness connectors from the bulkhead connections
     

  8.  
  9. Disconnect the following electrical connections:

    Engine Coolant Temperature (ECT) sensor
     
    Oil pressure switch
     
    Crankshaft Position (CKP) sensor
     
    Knock Sensor (KS)
     
    Camshaft Position (CMP) sensor
     
    Ignition coil
     

  10.  
  11. Remove or disconnect the following:

    Engine harness fixed clip from the bracket
     
    Fuel delivery, return and evaporative hoses
     
    Intake manifold bolts
     
    Intake manifold and gasket
     

  12.  

To install:

Click image to see an enlarged view

Fig. Intake manifold bolt location-2.0L engine

  1. Install or connect the following:

    Intake manifold and gasket
     
    Intake manifold bolts and tighten to 18 ft. lbs. (25 Nm)
     
    Fuel delivery, return and evaporative hoses
     
    Engine harness fixed clip from the bracket
     

  2.  
  3. Connect the following electrical connections:

    Oil pressure switch
     
    CKP sensor
     
    ECT sensor
     
    KS sensor
     
    CMP sensor
     
    Ignition coil
     
    Engine harness connectors to the bulkhead connections
     

  4.  
  5. Install or connect the following:

    Brake booster hose
     
    Engine coolant temperature hoses to the throttle body
     
    Emission hose to the PCV valve
     
    Pressure hose to the intake duct
     

  6.  
  7. Install the power steering pump on the bracket by performing the following steps:
    1. Install the power steering tank on the bracket.
    2.  
    3. Attach the power steering switch connection.
    4.  
    5. Install the bolts that attach the power steering pump bracket and tighten to 16 ft. lbs. (22 Nm).
    6.  
    7. Attach the power steering pump pipe brackets to the intake manifold.
    8.  
    9. Install the V-belt.
    10.  

  8.  
  9. Install or connect the following:

    Coolant filler tank
     
    Accelerator cable
     
    Intercooler
     
    Air cleaner filter
     
    Air cleaner upper cover and boot
     
    Engine undercover
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine and allow it to reach operating temperature. Check for leaks and test drive the vehicle.
  14.  

2.2L Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly-2.2L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if necessary
     

  6.  
  7. Drain the cooling system into a suitable container.

    Mass Air Flow (MAF) sensor electrical connector, if equipped
     
    Intake Air Temperature (IAT) sensor electrical connector, if equipped
     
    Clamp that connects the air intake duct to the air intake chamber
     
    Air cleaner cover clips
     
    Blow-by hose from the air intake duct
     
    Air intake duct and air cleaner cover as an assembly
     
    Air cleaner element
     

  8.  
  9. Loosen the clamp that connects the air intake chamber to the throttle body

    Air hoses and air intake chamber
     
    Accelerator cable and cruise control cable, if equipped
     
    Vacuum hoses from the pressure sources switching solenoid valve
     
    Resonator chamber
     
    Power steering pump drive belt cover(s) and belt
     
    Power steering pipe brackets from the right side of the intake manifold
     
    Power steering pump from bracket, then position on the right side wheel apron; do not disconnect the fluid lines
     
    Fuel pipe protector, if equipped
     
    Spark plug wires and electrical connector from ignition coil
     
    Positive Crankcase Ventilation (PCV) hose and pressure regulator vacuum hose from intake manifold
     
    Coolant hoses from the throttle body
     
    Engine coolant hose and air by-pass hose from the idle air control solenoid valve
     
    Brake booster hose
     
    Cruise control vacuum hose, if equipped
     
    Exhaust Gas Recirculation (EGR) pipe, on 2.2L engines with automatic transaxle
     
    Canister hoses from the pipes
     
    Engine harness connectors from bulkhead harness connectors, then remove from bracket
     
    Engine Coolant Temperature (ECT) sensor connector and thermometer connector, if equipped
     
    Knock sensor connector
     
    Crankshaft Position (CKP) and Camshaft Position (CMP) sensor connectors
     
    Oil pressure switch connector
     
    Fuel supply lines
     
    Intake manifold bolts
     
    Intake manifold and discard the gaskets
     

  10.  
  11. Clean all gasket material from both mating surfaces.
  12.  

To install:

  1. Use a straightedge and a feeler gauge to inspect the intake manifold for flatness. Distortion should not exceed 0.020 in. (0.5mm).
  2.  
  3. Install or connect the following:

    Intake manifold to the engine. Tighten the retaining bolts to 16.7-19.5 ft. lbs. (23-27 Nm).
     
    Fuel lines
     
    Oil pressure switch electrical connector
     
    CKP and CMP sensors
     
    Knock sensor
     
    ECT sensor and thermometer connectors
     
    Engine harness connector to the bracket and bulkhead
     
    Canister hoses, if disconnected
     
    Install the EGR pipe, if removed
     
    Cruise control vacuum hose, if equipped
     
    Brake booster vacuum hose
     
    Air bypass hose to the FICD solenoid valve
     
    PCV valve hose to the manifold
     
    Coolant hoses to throttle body
     
    Electrical connector and spark plug wires to ignition coil
     
    Fuel pipe protector, if equipped
     
    Power steering pump to bracket
     
    Power steering pump bolts and tighten to 13-16.6 ft. lbs. (17.6-22.6 Nm)
     
    Power steering brackets to the right side of the intake manifold
     
    Power steering pump belt and adjust the belt
     
    Power steering pump belt cover
     
    Vacuum hoses to pressure sources switching solenoid valve
     
    Accelerator cable and cruise control cable, if equipped
     
    Air intake chamber and hoses
     
    Air cleaner element, and the upper cover and duct as a unit
     
    MAF sensor electrical connector
     
    Engine cover, if equipped
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and allow it to reach operating temperature. Check for leaks and test drive the vehicle.
  8.  



Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly-2.2L engine

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if necessary
     

  6.  
  7. Drain the cooling system into a suitable container.

    Mass Air Flow (MAF) sensor electrical connector for 1998-99 vehicles, except California vehicles
     
    Intake Air Temperature (IAT) sensor electrical connector for 1999 California vehicles
     
    Clamp that connects the air intake duct to the air intake chamber
     
    Air cleaner cover clips
     
    Blow-by hose from the air intake duct
     
    Air intake duct and air cleaner cover as an assembly
     
    Air cleaner element
     

  8.  
  9. Loosen the clamp that connects the air intake chamber to the throttle body

    Air hoses and air intake chamber
     
    Accelerator cable and cruise control cable, if equipped
     
    Vacuum hoses from the pressure sources switching solenoid valve
     
    Resonator chamber on 1999 California models and all 2000-02 models
     
    Power steering pump drive belt cover(s) and belt
     
    Power steering pipe brackets from the right side of the intake manifold
     
    Power steering pump from bracket, then position on the right side wheel apron; do not disconnect the fluid lines
     
    Fuel pipe protector, if equipped
     
    Spark plug wires and electrical connector from ignition coil
     
    Positive Crankcase Ventilation (PCV) hose and pressure regulator vacuum hose from intake manifold
     
    Coolant hoses from the throttle body
     
    Engine coolant hose and air by-pass hose from the idle air control solenoid valve
     
    Brake booster hose
     
    Cruise control vacuum hose, if equipped
     
    Exhaust Gas Recirculation (EGR) pipe, on 2.2L engines with automatic transaxle
     
    Canister hoses from the pipes
     
    Engine harness connectors from bulkhead harness connectors, then remove from bracket
     
    Engine Coolant Temperature (ECT) sensor connector and thermometer connector, if equipped
     
    Knock sensor connector
     
    Crankshaft Position (CKP) and Camshaft Position (CMP) sensor connectors
     
    Oil pressure switch connector
     
    Fuel supply lines
     
    Intake manifold bolts
     
    Intake manifold and discard the gaskets
     

  10.  
  11. Clean all gasket material from both mating surfaces.
  12.  

To install:

  1. Use a straightedge and a feeler gauge to inspect the intake manifold for flatness. Distortion should not exceed 0.020 in. (0.5mm).
  2.  
  3. Install or connect the following:

    Intake manifold to the engine. Tighten the retaining bolts to 16.7-19.5 ft. lbs. (23-27 Nm).
     
    Fuel lines
     
    Oil pressure switch electrical connector
     
    CKP and CMP sensors
     
    Knock sensor
     
    ECT sensor and thermometer connectors
     
    Engine harness connector to the bracket and bulkhead
     
    Canister hoses, if disconnected
     
    Install the EGR pipe, if removed
     
    Cruise control vacuum hose, if equipped
     
    Brake booster vacuum hose
     
    Air bypass hose to the FICD solenoid valve
     
    PCV valve hose to the manifold
     
    Coolant hoses to throttle body
     
    Electrical connector and spark plug wires to ignition coil
     
    Fuel pipe protector, if equipped
     
    Power steering pump to bracket
     
    Power steering pump bolts and tighten to 13-16.6 ft. lbs. (17.6-22.6 Nm)
     
    Power steering brackets to the right side of the intake manifold
     
    Power steering pump belt and adjust the belt
     
    Power steering pump belt cover
     
    Vacuum hoses to pressure sources switching solenoid valve
     
    Accelerator cable and cruise control cable, if equipped
     
    Air intake chamber and hoses
     
    Air cleaner element, and the upper cover and duct as a unit
     
    MAF sensor electrical connector
     
    Engine cover, if equipped
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and allow it to reach operating temperature. Check for leaks and test drive the vehicle.
  8.  



Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly-2.2L engine

  1. Release the fuel system pressure.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if necessary
     

  4.  
  5. Drain the cooling system into a suitable container.

    Mass Air Flow (MAF) sensor electrical connector for 1998-99 vehicles, except California vehicles
     
    Intake Air Temperature (IAT) sensor electrical connector for 1999 California vehicles
     
    Clamp that connects the air intake duct to the air intake chamber
     
    Air cleaner cover clips
     
    Blow-by hose from the air intake duct
     
    Air intake duct and air cleaner cover as an assembly
     
    Air cleaner element
     

  6.  
  7. Loosen the clamp that connects the air intake chamber to the throttle body

    Air hoses and air intake chamber
     
    Accelerator cable and cruise control cable, if equipped
     
    Vacuum hoses from the pressure sources switching solenoid valve
     
    Resonator chamber on 1999 California models and all 2000-01 models
     
    Power steering pump drive belt cover(s) and belt
     
    Power steering pipe brackets from the right side of the intake manifold
     
    Power steering pump from bracket, then position on the right side wheel apron; do not disconnect the fluid lines
     
    Fuel pipe protector, if equipped
     
    Spark plug wires and electrical connector from ignition coil
     
    Positive Crankcase Ventilation (PCV) hose and pressure regulator vacuum hose from intake manifold
     
    Coolant hoses from the throttle body
     
    Engine coolant hose and air by-pass hose from the idle air control solenoid valve
     
    Brake booster hose
     
    Cruise control vacuum hose, if equipped
     
    Exhaust Gas Recirculation (EGR) pipe, on 2.2L engines with automatic transaxle
     
    Canister hoses from the pipes
     
    Engine harness connectors from bulkhead harness connectors, then remove from bracket
     
    Engine Coolant Temperature (ECT) sensor connector and thermometer connector, if equipped
     
    Knock sensor connector
     
    Crankshaft Position (CKP) and Camshaft Position (CMP) sensor connectors
     
    Oil pressure switch connector
     
    Fuel supply lines
     
    Intake manifold bolts
     
    Intake manifold and discard the gaskets
     

  8.  
  9. Clean all gasket material from both mating surfaces.
  10.  

To install:

  1. Use a straightedge and a feeler gauge to inspect the intake manifold for flatness. Distortion should not exceed 0.020 in. (0.5mm).
  2.  
  3. Install or connect the following:

    Intake manifold to the engine. Tighten the retaining bolts to 16.7-19.5 ft. lbs. (23-27 Nm).
     
    Fuel lines
     
    Oil pressure switch electrical connector
     
    CKP and CMP sensors
     
    Knock sensor
     
    ECT sensor and thermometer connectors
     
    Engine harness connector to the bracket and bulkhead
     
    Canister hoses, if disconnected
     
    Install the EGR pipe, if removed
     
    Cruise control vacuum hose, if equipped
     
    Brake booster vacuum hose
     
    Air bypass hose to the FICD solenoid valve
     
    PCV valve hose to the manifold
     
    Coolant hoses to throttle body
     
    Electrical connector and spark plug wires to ignition coil
     
    Fuel pipe protector, if equipped
     
    Power steering pump to bracket
     
    Power steering pump bolts and tighten to 13-16.6 ft. lbs. (17.6-22.6 Nm)
     
    Power steering brackets to the right side of the intake manifold
     
    Power steering pump belt and adjust the belt
     
    Power steering pump belt cover
     
    Vacuum hoses to pressure sources switching solenoid valve
     
    Accelerator cable and cruise control cable, if equipped
     
    Air intake chamber and hoses
     
    Air cleaner element, and the upper cover and duct as a unit
     
    MAF sensor electrical connector
     
    Engine cover, if equipped
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and allow it to reach operating temperature. Check for leaks and test drive the vehicle.
  8.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove or disconnect the following:

    Mass Air Flow (MAF) sensor connector, if necessary
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     

  8.  
  9. Properly release the fuel pressure.

    Accelerator cable and the cruise control cable, if equipped
     
    Resonator chamber, if equipped
     
    V-belt cover(s)
     

  10.  
  11. Loosen the lock bolt and slider bolt, then remove the power steering belt
  12.  
  13. Remove or disconnect the following:

    Power steering pipe bracket-to-manifold bolts
     
    Bolts holding the power steering pump to the bracket
     
    Connector from the power steering pump switch, if equipped
     
    Power steering pump, and place on the right side wheel apron. Do NOT disconnect the fluid lines.
     
    Spark plug wires from the spark plugs
     
    Positive Crankcase Ventilation (PCV) hose and vacuum hose from the intake manifold
     
    Engine coolant hoses from the throttle body
     
    Brake booster hose
     
    Air cleaner case stay (right side) and engine harness bracket, if necessary
     
    Engine harness connectors form the bulkhead harness connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Knock sensor, Camshaft Position (CMP) sensor and Crankshaft Position (CKP) sensor electrical connectors
     
    Oil pressure switch
     
    Fuel hoses from the fuel pipes
     
    Intake manifold mounting bolts
     
    Intake manifold and discard the gaskets
     

  14.  


NOTE
The intake manifold sits on pins that protrude from the cylinder heads. Be sure the pins remain in the cylinder heads.

To install:



Click image to see an enlarged view

Fig. Exploded view of the intake manifold and related components-2.5L engine

  1. Install or connect the following:

    New gaskets
     
    Intake manifold to the engine. Tighten the mounting bolts to 16.7-19.5 ft. lbs. (23-27 Nm).
     
    Fuel hoses to the fuel pipes, be sure to secure the hoses with new clamps
     
    Knock sensor, CMP sensor, CKP sensor, oil pressure switch and ECT sensor wiring
     
    Engine harness bracket and engine harness connectors to bulkhead connectors
     
    EGR pipe, if removed
     
    Brake booster hose
     
    Engine coolant hose and air bypass hose to idle air control solenoid valve, if removed
     
    Engine coolant hoses to the throttle body
     
    PCV hoses to intake manifold
     
    Spark plug wires to ignition coil or plugs, as applicable
     
    Power steering pump to bracket. Tighten the bolts to 13-16.6 ft. lbs. (17.6-22.6 Nm).
     
    Power steering pipe brackets on right side of the intake manifold
     
    Bolt, which installs the power steering pump stiffener on the engine block, to 14.4-17.3 ft. lbs. (20-24 Nm)
     
    Power steering pump belt and adjust the belt as necessary
     
    V-belt cover(s)
     
    Resonator chamber, if equipped
     
    Accelerator cable and the cruise control cable, if equipped
     
    Air cleaner assembly
     
    MAF sensor connector, if disconnected
     

  2.  
  3. Connect the negative battery cable and refill the cooling system. Start the engine, and bleed the cooling system. Check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove or disconnect the following:

    Mass Air Flow (MAF) sensor connector, if necessary
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     

  8.  
  9. Properly release the fuel pressure.
  10.  
  11. Remove or disconnect the following:

    Accelerator cable and the cruise control cable, if equipped
     
    Resonator chamber, if equipped
     
    V-belt cover(s)
     

  12.  
  13. Loosen the lock bolt and slider bolt, then remove the power steering belt
  14.  
  15. Remove or disconnect the following:
    NOTE
    The intake manifold sits on pins that protrude from the cylinder heads. Be sure the pins remain in the cylinder heads.



    Power steering pipe bracket-to-manifold bolts
     
    Bolts holding the power steering pump to the bracket
     
    Connector from the power steering pump switch, if equipped
     
    Power steering pump, and place on the right side wheel apron. Do NOT disconnect the fluid lines.
     
    Spark plug wires from the ignition coil and igniter, on 1998-99 vehicles, or from the spark plugs, on 2000-02 vehicles
     
    Positive Crankcase Ventilation (PCV) hose and vacuum hose from the intake manifold
     
    Engine coolant hoses from the throttle body
     
    Engine coolant hose and air bypass hose from the idle air control solenoid valve, on 1998 vehicles
     
    Brake booster hose
     
    EGR pipe, on 1998 vehicles
     
    Engine harness bracket from transmission housing, on 1998 vehicles
     
    Air cleaner case stay (right side) and engine harness bracket, on 1999-02 vehicles
     
    Engine harness connectors form the bulkhead harness connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Knock sensor, Camshaft Position (CMP) sensor and Crankshaft Position (CKP) sensor electrical connectors
     
    Oil pressure switch
     
    Fuel hoses from the fuel pipes
     
    Intake manifold mounting bolts
     
    Intake manifold and discard the gaskets
     

  16.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the intake manifold and related components-2.5L engine

  1. Install or connect the following:

    New gaskets
     
    Intake manifold to the engine. Tighten the mounting bolts to 16.7-19.5 ft. lbs. (23-27 Nm).
     
    Fuel hoses to the fuel pipes, be sure to secure the hoses with new clamps
     
    Knock sensor, CMP sensor, CKP sensor, oil pressure switch and ECT sensor wiring
     
    Engine harness bracket and engine harness connectors to bulkhead connectors
     
    EGR pipe, if removed
     
    Brake booster hose
     
    Engine coolant hose and air bypass hose to idle air control solenoid valve, if removed
     
    Engine coolant hoses to the throttle body
     
    PCV hoses to intake manifold
     
    Spark plug wires to ignition coil or plugs, as applicable
     
    Power steering pump to bracket. Tighten the bolts to 13-16.6 ft. lbs. (17.6-22.6 Nm).
     
    Power steering pipe brackets on right side of the intake manifold
     
    Bolt, which installs the power steering pump stiffener on the engine block, to 14.4-17.3 ft. lbs. (20-24 Nm)
     
    Power steering pump belt and adjust the belt as necessary
     
    V-belt cover(s)
     
    Resonator chamber, if equipped
     
    Accelerator cable and the cruise control cable, if equipped
     
    Air cleaner assembly
     
    MAF sensor connector, if disconnected
     

  2.  
  3. Connect the negative battery cable and refill the cooling system. Start the engine, and bleed the cooling system. Check for leaks.
  4.  



Click image to see an enlarged view

Fig. Intake manifold and related components-1998-2004 2.5L SOHC engine



Click image to see an enlarged view

Fig. Intake manifold and related components-1998-2004 2.5L DOHC engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Remove or disconnect the following:

    Mass Air Flow (MAF) sensor connector, if necessary
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     

  6.  
  7. Properly release the fuel pressure.

    Accelerator cable and the cruise control cable, if equipped
     
    Resonator chamber, if equipped
     
    V-belt cover(s)
     

  8.  
  9. Loosen the lock bolt and slider bolt, then remove the power steering belt
  10.  
  11. Remove or disconnect the following:
    NOTE
    The intake manifold sits on pins that protrude from the cylinder heads. Be sure the pins remain in the cylinder heads.



    Power steering pipe bracket-to-manifold bolts
     
    Bolts holding the power steering pump to the bracket
     
    Connector from the power steering pump switch, if equipped
     
    Power steering pump, and place on the right side wheel apron. Do NOT disconnect the fluid lines.
     
    Spark plug wires from the ignition coil and igniter, on 1998-99 vehicles, or from the spark plugs, on 2000-04 vehicles
     
    Positive Crankcase Ventilation (PCV) hose and vacuum hose from the intake manifold
     
    Engine coolant hoses from the throttle body
     
    Brake booster hose
     
    EGR pipe, on 1998 vehicles
     
    Engine harness bracket from transmission housing, on 1998 vehicles
     
    Air cleaner case stay (right side) and engine harness bracket, on 1999-04 vehicles
     
    Engine harness connectors form the bulkhead harness connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Knock sensor, Camshaft Position (CMP) sensor and Crankshaft Position (CKP) sensor electrical connectors
     
    Oil pressure switch
     
    Fuel hoses from the fuel pipes
     
    Intake manifold mounting bolts
     
    Intake manifold and discard the gaskets
     

  12.  

To install:

  1. Install or connect the following:

    New gaskets
     
    Intake manifold to the engine. Tighten the mounting bolts to 16.7-19.5 ft. lbs. (23-27 Nm).
     
    Fuel hoses to the fuel pipes, be sure to secure the hoses with new clamps
     
    Knock sensor, CMP sensor, CKP sensor, oil pressure switch and ECT sensor wiring
     
    Engine harness bracket and engine harness connectors to bulkhead connectors
     
    EGR pipe, if removed
     
    Brake booster hose
     
    Engine coolant hose and air bypass hose to idle air control solenoid valve, if removed
     
    Engine coolant hoses to the throttle body
     
    PCV hoses to intake manifold
     
    Spark plug wires to ignition coil or plugs, as applicable
     
    Power steering pump to bracket. Tighten the bolts to 13-16.6 ft. lbs. (17.6-22.6 Nm).
     
    Power steering pipe brackets on right side of the intake manifold
     
    Bolt, which installs the power steering pump stiffener on the engine block, to 14.4-17.3 ft. lbs. (20-24 Nm)
     
    Power steering pump belt and adjust the belt as necessary
     
    V-belt cover(s)
     
    Resonator chamber, if equipped
     
    Accelerator cable and the cruise control cable, if equipped
     
    Air cleaner assembly
     
    MAF sensor connector, if disconnected
     

  2.  
  3. Connect the negative battery cable and refill the cooling system. Start the engine, and bleed the cooling system. Check for leaks.
  4.  



Click image to see an enlarged view

Fig. Intake manifold and related components-2005 2.5L SOHC engine



Click image to see an enlarged view

Fig. Intake manifold and related components-2005 2.5L DOHC engine

  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable. Drain the engine coolant.
  4.  
  5. If equipped, remove the under cover.
  6.  
  7. Remove the air intake duct, air cleaner case and air intake chamber.
  8.  
  9. If equipped, remove the intercooler.
  10.  
  11. Remove the alternator.
  12.  
  13. If equipped with DOHC engine, remove the coolant filler tank.
  14.  
  15. If equipped with SOHC engine, remove the spark plug wires.
  16.  
  17. Disconnect the engine coolant hoses from the throttle body. Disconnect the brake booster hose.
  18.  
  19. Disconnect the PCV hose from the intake manifold. Disconnect the engine harness electrical connectors from the bulkhead harness connectors.
  20.  
  21. Disconnect the engine coolant temperature sensor electrical connector, knock sensor electrical connector and crankshaft position sensor connector.
  22.  
  23. Disconnect the power steering pump switch electrical connector, oil pressure switch connector and camshaft sensor connector.
  24.  
  25. If equipped with DOHC engine, disconnect the oil flow solenoid valve electrical connector and the ignition coil connector.
  26.  
  27. If equipped with SOHC engine, remove the EGR pipe from the intake manifold and disconnect the fuel lines from the fuel pipe.
  28.  
  29. If equipped with DOHC engine, disconnect the fuel delivery hose, return hose and evaporation hose.
  30.  
  31. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.
  32.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new intake manifold gaskets. Torque the manifold retaining bolts to specification and in alternating sequence.
  4.  
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6.  
  7. Start the engine and check for leaks, correct as required.
  8.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly release the fuel pressure.
  6.  
  7. Remove or disconnect the following:

    Air intake duct, air cleaner upper cover and the air cleaner element
     
    Resonator chamber
     
    Accelerator cable and the cruise control cable, if equipped
     
    Power steering pipe bracket-to-manifold bolts
     
    V-belt
     
    Bolts holding the power steering pump to the bracket
     
    Connector from the power steering pump switch
     
    Power steering pump, and place on the right side wheel apron. Do NOT disconnect the fluid lines.
     
    Washer reservoir bolts, hose from the front washer motor and connector from the rear washer motor.
     
    Rear washer hose from the motor and plug the hose
     
    Washer reservoir aside
     
    Positive Crankcase Ventilation (PCV) hose from the cylinder head cover
     
    Engine coolant hoses from the throttle body
     
    Brake booster hose
     
    Exhaust Gas Recirculation (EGR) pipe from the valve being careful not to drop the gaskets
     
    Engine harness connectors from the bulkhead connectors
     
    Engine ground terminal from the manifold
     
    Fuel hoses from the fuel pipes
     
    Ground cable from the fuel pipe protector on the left hand side
     
    Fuel pipe protector on the left hand side
     
    Air assist hose on the left hand side
     
    Bolt securing the fuel injector pipe to the cylinder head on the left hand side
     
    Ground cable from the fuel pipe protector on the right hand side
     
    Fuel pipe protector on the right hand side
     
    Air assist hose on the right hand side
     
    Bolt securing the fuel injector pipe to the cylinder head on the right hand side
     
    Intake manifold mounting bolts
     
    Intake manifold and discard the gaskets
     

  8.  

To install:



Click image to see an enlarged view

Fig. Exploded view of the intake manifold and related components-3.0L engine

  1. Install or connect the following:

    New gaskets
     
    Intake manifold to the engine. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
     
    Bolt securing the fuel injector pipe to the cylinder head on the right hand side. Tighten to 14 ft. lbs. (19 Nm).
     
    Air assist hose on the right hand side
     
    Fuel pipe protector on the right hand side. Tighten to 14 ft. lbs. (19 Nm).
     
    Ground cable from the fuel pipe protector on the right hand side
     
    Bolt securing the fuel injector pipe to the cylinder head on the left hand side. Tighten to 14 ft. lbs. (19 Nm).
     
    Air assist hose on the left hand side
     
    Fuel pipe protector on the left hand side. Tighten to 14 ft. lbs. (19 Nm).
     
    Ground cable to the fuel pipe protector on the left hand side
     
    EGR pipe to the valve using new gaskets and tighten to 5 ft. lbs. (7 Nm)
     
    Fuel hoses to the fuel pipes
     
    Engine ground terminal to the manifold
     
    Engine harness connectors to the bulkhead connectors
     
    Brake booster hose
     
    Engine coolant hoses to the throttle body
     
    PCV hose to the cylinder head cover
     
    Power steering pump
     
    Connector to the power steering pump switch
     
    Bolts holding the power steering pump to the bracket and tighten to 15 ft. lbs. (20 Nm)
     
    V-belt
     
    Rear washer hose to the motor
     
    Washer reservoir hose to the front washer motor and connector to the rear washer motor.
     
    Washer reservoir
     
    Accelerator cable and the cruise control cable, if equipped
     
    Resonator chamber
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     

  2.  
  3. Connect the negative battery cable and refill the cooling system. Start the engine, and bleed the cooling system. Check for leaks.
  4.  



Click image to see an enlarged view

Fig. Intake manifold and related components-2002-2004 3.0L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Properly release the fuel pressure.
  4.  
  5. Remove or disconnect the following:

    Air intake duct, air cleaner upper cover and the air cleaner element
     
    Resonator chamber
     
    Accelerator cable and the cruise control cable, if equipped
     
    Power steering pipe bracket-to-manifold bolts
     
    V-belt
     
    Bolts holding the power steering pump to the bracket
     
    Connector from the power steering pump switch
     
    Power steering pump, and place on the right side wheel apron. Do NOT disconnect the fluid lines.
     
    Washer reservoir bolts, hose from the front washer motor and connector from the rear washer motor.
     
    Rear washer hose from the motor and plug the hose
     
    Washer reservoir aside
     
    Positive Crankcase Ventilation (PCV) hose from the cylinder head cover
     
    Engine coolant hoses from the throttle body
     
    Brake booster hose
     
    Exhaust Gas Recirculation (EGR) pipe from the valve being careful not to drop the gaskets
     
    Engine harness connectors from the bulkhead connectors
     
    Engine ground terminal from the manifold
     
    Fuel hoses from the fuel pipes
     
    Ground cable from the fuel pipe protector on the left hand side
     
    Fuel pipe protector on the left hand side
     
    Air assist hose on the left hand side
     
    Bolt securing the fuel injector pipe to the cylinder head on the left hand side
     
    Ground cable from the fuel pipe protector on the right hand side
     
    Fuel pipe protector on the right hand side
     
    Air assist hose on the right hand side
     
    Bolt securing the fuel injector pipe to the cylinder head on the right hand side
     
    Intake manifold mounting bolts
     
    Intake manifold and discard the gaskets
     

  6.  

To install:

  1. Install or connect the following:

    New gaskets
     
    Intake manifold to the engine. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
     
    Bolt securing the fuel injector pipe to the cylinder head on the right hand side. Tighten to 14 ft. lbs. (19 Nm).
     
    Air assist hose on the right hand side
     
    Fuel pipe protector on the right hand side. Tighten to 14 ft. lbs. (19 Nm).
     
    Ground cable from the fuel pipe protector on the right hand side
     
    Bolt securing the fuel injector pipe to the cylinder head on the left hand side. Tighten to 14 ft. lbs. (19 Nm).
     
    Air assist hose on the left hand side
     
    Fuel pipe protector on the left hand side. Tighten to 14 ft. lbs. (19 Nm).
     
    Ground cable to the fuel pipe protector on the left hand side
     
    EGR pipe to the valve using new gaskets and tighten to 5 ft. lbs. (7 Nm)
     
    Fuel hoses to the fuel pipes
     
    Engine ground terminal to the manifold
     
    Engine harness connectors to the bulkhead connectors
     
    Brake booster hose
     
    Engine coolant hoses to the throttle body
     
    PCV hose to the cylinder head cover
     
    Power steering pump
     
    Connector to the power steering pump switch
     
    Bolts holding the power steering pump to the bracket and tighten to 15 ft. lbs. (20 Nm)
     
    V-belt
     
    Rear washer hose to the motor
     
    Washer reservoir hose to the front washer motor and connector to the rear washer motor.
     
    Washer reservoir
     
    Accelerator cable and the cruise control cable, if equipped
     
    Resonator chamber
     
    Air intake duct, air cleaner upper cover and the air cleaner element
     

  2.  
  3. Connect the negative battery cable and refill the cooling system. Start the engine, and bleed the cooling system. Check for leaks.
  4.  



Click image to see an enlarged view

Fig. Intake manifold and related components-2005 3.0L engine

  1. Properly relieve the fuel system pressure. Remove the fuel cap.
  2.  
  3. Disconnect the negative battery cable. Drain the engine coolant.
  4.  
  5. Remove the air cleaner case and air intake chamber.
  6.  
  7. Remove the alternator.
  8.  
  9. Disconnect the electrical connector from the throttle body. Disconnect the engine coolant hoses from the throttle body.
  10.  
  11. Disconnect the engine harness connector. Disconnect the PCV hose. Disconnect the brake booster hose. Disconnect the fuel hoses from the fuel pipe.
  12.  
  13. Remove the left side fuel line protector. Remove the engine harness from the left side fuel injector pipe. Remove the bolts which hold the fuel injector pipe to the left cylinder head.
  14.  
  15. Remove the right side fuel line protector. Remove the engine harness from the right side fuel injector pipe. Remove the bolts which hold the fuel injector pipe to the right cylinder head.
  16.  
  17. Remove the right and left intake manifold retaining bolts. Remove the intake manifold from the engine.
  18.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new intake manifold O-rings. Torque the manifold retaining bolts to specification and in alternating sequence.
  4.  
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6.  
  7. Start the engine and check for leaks, correct as required.
  8.  

3.3L Engines


Click image to see an enlarged view

Fig. Intake manifold assembly-3.3L engine


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the collector cover.
  8.  
  9. Disconnect the accelerator cable and cruise control cable from the throttle lever, if equipped.
  10.  
  11. Remove the air intake ducts.
  12.  
  13. Disconnect the electrical harnesses from the intake manifold sensors and brackets.
  14.  
  15. Detach the electrical connector from the auxiliary air control valve.
  16.  
  17. Disconnect and cap the two coolant hoses from the underside of the throttle body.
  18.  
  19. Disconnect the auxiliary air control valve hose from the throttle body.
  20.  
  21. Disconnect the PCV hose. Remove the blow-by hose from the cylinder head cover.
  22.  
  23. Disconnect the EGR control hoses from the intake manifold. Remove the EGR pipe and cover.
  24.  
  25. Disconnect the power steering pump electrical harness.
  26.  
  27. Disconnect the power brake booster vacuum hose.
  28.  
  29. Disconnect and cap the fuel lines from the fuel pipes.
  30.  
  31. Remove the drive belt cover and drive belts.
  32.  
  33. Unfasten the electrical connections from the alternator.
  34.  
  35. Remove the alternator. Refer to Section 2 for removal and installation steps.
  36.  
  37. Remove the A/C compressor mounting bolts and position the A/C compressor aside with the refrigerant lines attached.
  38.  
  39. Remove the intake manifold.
  40.  
  41. Clean all gasket material from both mating surfaces.
  42.  
  43. Installation is the reverse of removal. Tighten all components to specification and pay particular attention to the following:
  44.  
  45. Using new gaskets, tighten the intake manifold bolts to 18 ft. lbs. (24 Nm).
  46.  
  47. Install the drive belts and tension as necessary. Install the drive belt cover.
  48.  
  49. Connect the fuel lines to the fuel pipes and attach all vacuum lines.
  50.  
  51. Pressurize the fuel system and check for leaks.
  52.  

 
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