To remove the intake manifold, first relieve the fuel system pressure. If equipped, lift the engine cover off the ballstuds and remove it. Disconnect the cable from the negative battery terminal. Remove the air cleaner outlet hose and, for 1.5L models, take out the air filter housing. For 1.5L, 1.6L, and 2.3L engines, remove the alternator. Disconnect the electrical connectors for the swirl control, throttle body, MAP sensor, and oil pressure sender, then remove the air intake duct from the throttle body. On turbocharged models, remove the Charge Air Cooler (CAC) inlet and outlet tubes, and for 1.5L models, take out the CAC from the intake manifold. For 2.0L models, disconnect the electrical connectors for the throttle body, Fuel Rail Pressure (FRP) sensor, and the Manifold Absolute Pressure (MAP) sensor. Disengage the EVAP line and heater hose retainers underneath the manifold, then remove the EVAP canister purge valve. On later models, release the vacuum hoses from the intake manifold by depressing the red quick-connect lock ring while pulling the hose upward. For 2013 and later 2.5L models, squeeze the two crankcase vent oil separator tube tabs and disconnect the tube from the back side of the intake manifold. If equipped, disconnect the AIR pump connector and remove the pump. Release the harness clips and set aside the wiring harness at the top of the intake manifold. For 1.5L engines, remove the Turbo outlet pipe. For 2.0L, 2.3L, and 2.5L engines, remove the fuel rail heat shield if equipped. Remove the intake manifold fasteners and pull the intake manifold away from the engine enough to access and disconnect the EGR pipe if equipped, and the crankcase vent hose from the oil separator, squeezing the two clips on the vent hose to release it. Note that there are two sizes of bolts, so make note of their original installation locations. For installation, 2.0L, 2.3L, and 2.5L engines require individual gaskets for each of the four ports of the intake manifold, while 1.5L and 1.6L engines use one gasket for all ports. Using new manifold gasket(s), install the intake manifold, tightening the bolts in sequence for 1.5L engines, and for other models, tighten the bolts and nuts in several stages, working from the center out. Installation is otherwise the reverse of removal.
