Removal procedure
1. Disconnect the negative battery cable.
2. Drain the engine coolant. See Section 1D2, Engine Cooling System - FAM II 2.4D.
3. Disconnect the intake air temperature sensor connector (IAT).
4. Loosen the clamp and disconnect the air filter outlet hose from the electronic throttle body with resonator attached.
5. Disconnect the electronic throttle control module sensor connector (ETC).
6. Disconnect the manifold absolute pressure sensor (IDA).
7. Disconnect the coolant hoses from the electronic throttle body.
8. Disconnect all necessary vacuum hoses, including the brake booster vacuum hose at the intake manifold.
9. Remove the alternator top bracket.
10. Remove the alternator to intake manifold bracket bolt on the intake manifold and loosen the bolt on the alternator.
11. Remove the fuel rail assembly. See Section 1F2, Engine Controls - FAM II 2.4D.
12. Remove the EVAP canister purge valve. See Section 1F2, Engine Controls - FAM II 2.4D.
13. Remove the intake manifold support bracket screw on the cylinder block and intake manifold.
14. Remove the intake manifold support bracket.
15. Loosen the locking screw of the ground terminal.
16. Remove the intake manifold retaining screws and nuts in the following order.
17. Remove the intake manifold.
18. Remove the intake manifold gasket.
19. Clean the sealing surfaces of the intake manifold and cylinder head.
Installation procedure
1. Install a new intake manifold gasket.
2. Install the intake manifold.
3. Install the intake manifold retaining screws and nuts in the order shown below.
Tighten
Tighten the intake manifold set screws and nuts to 22 Nm (16 lb-ft).
4. Screw the retaining bolt of the ground wire terminal to the intake manifold.
5. Install the intake manifold support bracket.
Tighten
Tighten the intake manifold support bracket bolts on the intake manifold and cylinder block to 25 Nm (18 lb-ft).
6. Install the alternator top bracket.
Tighten
Tighten lock bolts (1) upper bracket of the generator with a torque of 25 Nm (18 lb-ft), and the bolt (2) torque 35 Nm (26 lb-ft).7.
7. Install the alternator mounting bracket to the intake manifold.
Tighten
Tighten the retaining bolt for the alternator-to-inlet manifold bracket (3) torque 35 Н·м (26 lb-ft), and the bolt (4) torque 25 Н·м (18 lb-ft).
8. Install the fuel rail assembly. See Section 1F2, Engine Controls - FAM II 2.4D.
Tighten
Tighten the fuel rail assembly retaining screws to 25 Nm (18 lb-ft).
9. Install the EVAP canister purge valve.
Tighten
Tighten the canister purge solenoid valve support bracket bolt to 5 Nm (44 lb-in).
10. Connect all necessary vacuum lines that were previously disconnected.
11. Connect the MAP sensor connector.
12. Connect the electronic throttle control unit sensor connector (ETC).
13. Connect the coolant hoses to the electronic throttle body.
14. Connect the air filter outlet hose to the electronic throttle body connected to the resonator.
15. Connect the IAT sensor connector.
16. Connect the negative battery cable.
17. Refill the engine cooling system. See Section 1D2, Engine Cooling System - FAM II 2.4D.
