Intake Manifold Removal and Installation

Exploded View - K24A3 engine Exploded View - K20Z2 engine Removal

1. Remove the intake manifold cover.

1. Disconnect the intake air temperature (IAT) sensor connector (A).

1. Remove the vacuum hose (B) and breather pipe (C), then remove the intake air duct (D).

1. Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).

1. Remove the engine wire harness connectors.
   - Manifold absolute pressure (MAP) sensor connector
   - Throttle actuator connector

1. Remove the harness holder (A), harness bracket (B), and remove the harness clamp (C).

1. Remove the water bypass hoses, then plug the water bypass hoses.

1. K20Z2 engine: Remove the positive crankcase ventilation (PCV) hose.

1. K24A3 engine: Remove the vacuum hose.

1. Raise the vehicle on the hoist to full height.

1. Remove the connector (A), then remove the intake manifold bracket (B).

1. Lower the vehicle on the hoist.

1. Remove the intake manifold.

Installation

1. Install the intake manifold (A) with a new gasket (B), and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt.

1. Raise the vehicle on the hoist to full height.

1. Install the intake manifold bracket (A), then install the connector (B).

1. Lower the vehicle on the hoist.

1. Install the water bypass hoses.

1. K20Z2 engine: Install the PCV hose.

1. K24Z3 engine: Install the vacuum hose.

1. Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).

1. Install the harness holder (A), harness bracket (B), and install the harness clamp (C).

1. Connect the engine wire harness connectors.
   - Manifold absolute pressure (MAP) sensor connector
   - Throttle actuator connector

1. Install the intake air duct (A), then connect the IAT sensor connector (B), install the vacuum hose (C) and breather pipe (D).

1. Install the intake manifold cover.

1. Clean up any spilled engine coolant.

1. After installation, check that all tubes, hoses and connectors are installed correctly.

1. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.