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Intake Manifold

Engine, Cooling and Exhaust › Engine
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartIntake Manifold
ManufacturerCHY
OEM part #53034181AD
Price$290.00

Labor

Replace — Intake Manifold2.1 hr
Warranty 0.0 hrSkill B
Procedures
Intake Manifold: Specificationsreference
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INTAKE MANIFOLD Install the intake manifold retaining bolts Tighten 12 Nm (105 in. lbs.)
Intake Manifold - Removal15 steps
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  1. Bleed the fuel system. Service and Repair
  2. Disconnect the negative cable from battery.
  3. Remove the resonator assembly and air inlet hose.
  4. Drain the cooling system Service and Repair.
  5. If equipped with the heater return and supply cross over lines. Remove the lines and position aside.
  6. Disconnect the electronic throttle control (ETC) connector (3).
  7. Disconnect electrical connectors for the following components: -Coolant Temperature Sensor -Manifold Absolute Pressure (MAP) Sensor (2)
  8. Disconnect vapor purge hose, brake booster hose, and positive crankcase ventilation (PCV) hose.
  9. Disconnect and remove ignition coil towers.
  10. Remove the top oil dipstick tube retaining bolt.
  11. Remove the EGR tube (1) Exhaust Gas Recirculation (EGR) Valve - Removal.
  12. Remove fuel rail Fuel Rail - Removal.
  13. Remove throttle body assembly (1).
  14. Remove the intake manifold retaining fasteners in reverse order of tightening sequence.
  15. Remove the intake manifold.
Intake Manifold - Installation18 steps
△ CAUTION
Proper torque of the throttle body is critical to normal operation. If the throttle body is over-torqued, damage to the throttle body can occur resulting in throttle plate malfunction.
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  1. Install the intake manifold seals.
  2. Install the intake manifold.
  3. Install the intake manifold retaining bolts and tighten in sequence shown to 12 Nm (105 in. lbs.).
  4. Install the throttle body-to-intake manifold O-ring.
  5. Install the throttle body (1) to intake manifold.
  6. Install the four mounting bolts (2). Tighten bolts to 7 Nm (60 in. lbs.).
  7. Install electrical connector (3).
  8. Install the fuel rail.
  9. Install the EGR tube (1) Exhaust Gas Recirculation (EGR) Valve - Installation
  10. Install ignition coil towers.
  11. Connect electrical connectors for the following components: -Manifold Absolute Pressure (MAP) Sensor (2) -Coolant Temperature (CTS) Sensor -Ignition coil towers
  12. Install top oil dipstick tube retaining bolt.
  13. Connect Vapor purge hose, Brake booster hose, Positive crankcase ventilation (PCV) hose.
  14. If equipped, install the heater return and supply cross over lines.
  15. Fill the cooling system.
  16. Install the resonator assembly and air inlet hose.
  17. Connect the negative cable to battery.
  18. Using the scan tool, perform the ETC Relearn function.
Intake Manifold: Testing and Inspection4 steps
⚠ WARNING
Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or the fan. Do not wear loose clothing.
  1. Start the engine.
  2. Spray a small stream of water (spray bottle) at the suspected leak area.
  3. If engine RPM'S change, the area of the suspected leak has been found.
  4. Repair as required.
Intake Manifold: Description and Operationreference
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DESCRIPTION The intake manifold (Figure 1) is made of a composite material and features 300 mm (11.811 in.) long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of six individual press in place port gaskets (2) to prevent leaks. The throttle body attaches directly to the intake manifold.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
INTAKE MANIFOLD📷 1
The intake manifold is made of a composite material and features 300 mm (11.811 in.) long runners which maximizes low end torque. See Fig. 154.
The intake manifold uses single plane sealing which consist of six individual press in place port gaskets (2) to prevent leaks. The throttle body attaches directly to the intake manifold.
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INTAKE MANIFOLD LEAKS📷 1
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.
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CLOTHING.📷 1
1.   Start the engine.
  2.   Spray a small stream of water (spray bottle) at the suspected leak area.
  3.   If engine RPM'S change, the area of the suspected leak has been found.
  4.   Repair as required.
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INTAKE MANIFOLD📷 6
1 - THROTTLE BODY 2 - MOUNTING BOLTS 3 - ELEC. CONNECTOR
  1.   Bleed the fuel system. Refer to STANDARD PROCEDURE .
  2.   Disconnect the negative cable from battery.
  3.   Remove the resonator assembly and air inlet hose.
  4.   Drain the cooling system below coolant temperature sensor level.
  5.   Disconnect the electronic throttle control (ETC) connector (3).
1 - MOUNTING SCREWS 2 - MAP SENSOR 3 - ECT SENSOR 4 - FRONT OF INTAKE MANIFOLD
6. Disconnect electrical connectors for the following components: Coolant Temperature Sensor Manifold Absolute Pressure (MAP) Sensor (2)
 7.   Disconnect vapor purge hose, brake booster hose, and positive crankcase ventilation (PCV) hose.
 8.   Disconnect and remove ignition coil towers.
 9.   Remove the top oil dipstick tube retaining bolt.
10.   Remove the EGR tube (1). Refer to REMOVAL .
11.   Remove fuel rail. Refer to REMOVAL .
1 - THROTTLE BODY 2 - MOUNTING BOLTS 3 - ELEC. CONNECTOR
12. Remove throttle body assembly (1).
13. Remove the intake manifold retaining fasteners in reverse order of tightening sequence. 14. Remove the intake manifold.
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INTAKE MANIFOLD📷 3
1. Install the intake manifold seals. 2. Install the intake manifold. 3. Install the intake manifold retaining bolts and tighten in sequence shown in illustration to 12 N.m (105 in. lbs.).
1 - THROTTLE BODY 2 - MOUNTING BOLTS
3 - ELEC. CONNECTOR
CAUTION: Proper torque of the throttle body is critical to normal operation. If the throttle body is over-torqued, damage to the throttle body can occur resulting in throttle plate malfunction.
 4.   Install the throttle body-to-intake manifold O-ring.
 5.   Install the throttle body (1) to intake manifold.
 6.   Install the four mounting bolts (2). Tighten bolts to 7 N.m (60 in. lbs.).
 7.   Install electrical connector (3).
8. Install the fuel rail. 9. Install the EGR tube (1). Refer to INSTALLATION . 10. Install ignition coil towers.
1 - MOUNTING SCREWS 2 - MAP SENSOR 3 - ECT SENSOR 4 - FRONT OF INTAKE MANIFOLD
11. Connect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor (2) Coolant Temperature (CTS) Sensor Ignition coil towers 12. Install top oil dipstick tube retaining bolt. 13. Connect Vapor purge hose, Brake booster hose, Positive crankcase ventilation (PCV) hose. 14. Fill the cooling system. 15. Install the resonator assembly and air inlet hose. 16. Connect the negative cable to battery. 17. Using the scan tool, perform the ETC Relearn function.
MANIFOLD-EXHAUST
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