Tracker 2000-2004

Intake Manifold

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Removal & Installation



1.6L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake pipe
     
    Accelerator cable and bracket
     
    Transmission cable, if equipped
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector and hoses
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Coolant temperature gauge sender connector
     
    A/C coolant temperature switch connector, if equipped
     
    Evaporative Emission (EVAP) canister purge valve connector and vacuum line
     
    Exhaust Gas Recirculation (EGR) temperature sensor connector
     
    EGR vacuum valve connector
     
    EGR bypass valve connector
     
    EGR vacuum lines
     
    Fuel injector connectors
     
    Intake manifold ground cable
     
    Transmission vacuum line, if equipped
     
    Brake booster vacuum line
     
    Manifold Absolute Pressure (MAP) sensor vacuum line
     
    Fuel lines
     
    Upper radiator hose
     
    Coolant bypass hose
     
    Alternator bracket
     
    Intake manifold brackets
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Tighten the nuts to 17 ft. lbs. (23 Nm).
     
    Intake manifold brackets. Tighten the fasteners to 36 ft. lbs. (50 Nm).
     
    Alternator bracket. Tighten the fasteners to 36 ft. lbs. (50 Nm).
     
    Coolant bypass hose
     
    Upper radiator hose
     
    Fuel lines
     
    MAP sensor vacuum line
     
    Brake booster vacuum line
     
    Transmission vacuum line, if equipped
     
    Intake manifold ground cable
     
    Fuel injector connectors
     
    EGR vacuum lines
     
    EGR bypass valve connector
     
    EGR vacuum valve connector
     
    EGR temperature sensor connector
     
    EVAP canister purge valve connector and vacuum line
     
    A/C coolant temperature switch connector, if equipped
     
    Coolant temperature gauge sender connector
     
    ECT sensor connector
     
    IAC valve connector and hoses
     
    TP sensor connector
     
    Transmission cable, if equipped
     
    Accelerator cable and bracket
     
    Air intake pipe
     
    Negative battery cable
     

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

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake tube
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Evaporative Emissions (EVAP) canister purge valve connector and hose
     
    Intake manifold ground cable
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Fuel pressure regulator vacuum hose
     
    Intake manifold vacuum hose
     
    Throttle body coolant hoses
     
    Water bypass pipe
     
    Fuel lines
     
    Fuel supply manifold with injectors attached
     
    Intake manifold support brackets
     
    Intake manifold water pipe
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Tighten the fasteners to 17 ft. lbs. (23 Nm).
     
    Intake manifold water pipe
     
    Intake manifold front support bracket. Tighten the bolts to 36 ft. lbs. (50 Nm).
     
    Intake manifold rear support bracket. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Fuel supply manifold with injectors attached
     
    Fuel lines
     
    Water bypass pipe
     
    Throttle body coolant hoses
     
    Intake manifold vacuum hose
     
    Fuel pressure regulator vacuum hose
     
    PCV valve and hose
     
    Brake booster vacuum hose
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    MAP sensor connector
     
    Intake manifold ground cable
     
    EVAP canister purge valve connector and hose
     
    TP sensor connector
     
    IAC valve connector
     
    EGR valve connector
     
    Air intake tube
     
    Negative battery cable
     

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

2.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower bar
     
    Intake Air Temperature (IAT) sensor connector
     
    Surge tank cover
     
    Air intake assembly
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Throttle body coolant hoses
     
    Fuel injector connectors
     
    Throttle Position (TP) sensor connector
     
    Mass Air Flow (MAF) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Intake manifold ground cables
     
    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) canister purge valve connector and hoses
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Heater hoses
     
    EGR pipe
     
    Fuel lines
     
    Throttle body and intake collector
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with new gaskets. Tighten the fasteners to 16 ft. lbs. (23 Nm).
     
    Throttle body and intake collector with new gaskets. Tighten the fasteners to 102 inch lbs. (12 Nm).
     
    Fuel lines
     
    EGR pipe
     
    Heater hoses
     
    PCV valve and hose
     
    EGR valve connector
     
    EVAP canister purge valve connector and hoses
     
    Brake booster vacuum hose
     
    Intake manifold ground cables
     
    IAC valve connector
     
    MAF sensor connector
     
    TP sensor connector
     
    Fuel injector connectors
     
    Throttle body coolant hoses
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Air intake assembly
     
    Surge tank cover
     
    IAT sensor connector
     
    Strut tower bar
     
    Negative battery cable
     

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

 
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