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Home >> Alfa Romeo >> 2019 >> Giulia Base, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.0L - Engine (Service Information) >> Manifolds >> Manifold, Intake >> Removal And Installation >> Intake Manifold

Intake Manifold

REMOVAL 

  1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  2. Disconnect and isolate the negative battery cable.
  3. Drain the turbocharger cooling system. Refer to DRAINING AND FILLING THE TURBOCHARGER COOLING SYSTEM .
  4. Remove the top engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION COVER, ENGINE, REMOVAL AND INSTALLATION .
  5. Remove the engine belly pan. Refer to BELLY PAN, ENGINE, REMOVAL AND INSTALLATION .
  6. Remove the Mass Airflow (MAF) sensor. Refer to SENSOR, MASS AIRFLOW (MAF), REMOVAL AND INSTALLATION .
  7. Remove the air filter housing. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  8. Remove the side engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
  9. Remove the engine oil vapor intake pipe. Refer to SEPARATOR, OIL, REMOVAL AND INSTALLATION .
  10. Remove the air outlet pipe from turbocharger to throttle body. Refer to COOLER AND HOSES, CHARGE AIR, REMOVAL AND INSTALLATION .
  11. Remove the Powertrain Control Module (PCM) and PCM mounting bracket. Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL AND INSTALLATION .
  12. Remove the intake air pressure/temperature sensor. Refer to SENSOR, TMAP-INTAKE MANIFOLD, REMOVAL AND INSTALLATION .
  13. Remove the front fuel vapor line. Refer to LINES, FUEL VAPOR, REMOVAL AND INSTALLATION .
  14. Remove the fuel vapor vacuum solenoid valve. Refer to SOLENOID, EVAPORATIVE EMISSIONS PURGE, REMOVAL AND INSTALLATION .
    GC0194808Courtesy of CHRYSLER GROUP, LLC
  15. Disconnect the electrical connection (1) from the throttle body.
  16. Loosen the band (2) and disconnect the coolant supply pipe from the throttle body.
    GC0195313Courtesy of CHRYSLER GROUP, LLC
  17. Disconnect the electrical connection (1) from the charge air cooler coolant temperature sensor.
    GC0194357Courtesy of CHRYSLER GROUP, LLC
  18. Retract the clip (1) and disconnect the coolant supply connector from the charge air cooler.
    GC0195415Courtesy of CHRYSLER GROUP, LLC
  19. Disconnect the quick connector (1) and remove the coolant return pipe from the charge air cooler.
    GC0193953Courtesy of CHRYSLER GROUP, LLC
  20. Release the wiring retaining clips (1).
    GC0193039Courtesy of CHRYSLER GROUP, LLC
  21. Remove the two lower screws (1) securing the intake manifold.
    GC0194256Courtesy of CHRYSLER GROUP, LLC
  22. Remove the five upper screws (1) securing the intake manifold and remove it from the cylinder head.
    GC0193515Courtesy of CHRYSLER GROUP, LLC
  23. Loosen the band (1) and disconnect the coolant outlet pipe from the throttle body.
    GC0195010Courtesy of CHRYSLER GROUP, LLC
  24. Remove the intake manifold (1).
    GC0195357Courtesy of CHRYSLER GROUP, LLC
  25. Remove the screws (1a) and remove the throttle body (1b).
    GC0180979Courtesy of CHRYSLER GROUP, LLC
  26. Remove the throttle body gasket (1).
    GC0194551Courtesy of CHRYSLER GROUP, LLC
  27. Loosen the band and remove the fuel vapor pipe (1).
    GC0193035Courtesy of CHRYSLER GROUP, LLC
  28. Remove the toothed washers and remove the heat shield (1).
  29. Remove the seals (2).
    GC0193534Courtesy of CHRYSLER GROUP, LLC
  30. Remove the screws (1) and remove the fuel vapor solenoid valve support bracket.

INSTALLATION 

  1. Install the fuel vapor solenoid valve support bracket and tighten the screws.
  2. Install new gaskets on the intake manifold.
  3. Install the heat shield and tighten the screws.
  4. Install the fuel vapor pipe in position and close the band.
  5. Install a new gasket in the throttle body housing.
  6. Install the throttle body and tighten the fastening screws.
    GC0194996Courtesy of CHRYSLER GROUP, LLC
  7. Install the Intake manifold (1a), connect the coolant outlet pipe to the throttle body and close the retaining band; tighten the five upper screws (1b) to the proper specification Refer to TORQUE SPECIFICATIONS  .
    GC0193412Courtesy of CHRYSLER GROUP, LLC
  8. Tighten the two intake manifold lower screws (1) to the proper specification Refer to TORQUE SPECIFICATIONS  .
  9. Engage the wiring in the retaining clips.
  10. Connect the quick connector of the coolant return pipe to the charge air cooler.
  11. Connect the coolant supply pipe to the charge air cooler and engage the retaining clip.
  12. Connect the electrical connection to the charge air cooler coolant temperature sensor.
  13. Connect the coolant supply pipe to the throttle body and close the band.
  14. Connect the electrical connection to the throttle body.
  15. Install the fuel vapor vacuum solenoid valve. Refer to SOLENOID, EVAPORATIVE EMISSIONS PURGE, REMOVAL AND INSTALLATION .
  16. Install the front fuel vapor line. Refer to LINES, FUEL VAPOR, REMOVAL AND INSTALLATION .
  17. Install the intake air pressure/temperature sensor. Refer to SENSOR, TMAP-INTAKE MANIFOLD, REMOVAL AND INSTALLATION .
  18. Install the Powertrain Control Module (PCM) and PCM mounting bracket. Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL AND INSTALLATION .
  19. Install the air outlet pipe from turbocharger to throttle body. Refer to COOLER AND HOSES, CHARGE AIR, REMOVAL AND INSTALLATION .
  20. Install the engine oil vapor intake pipe. Refer to SEPARATOR, OIL, REMOVAL AND INSTALLATION .
  21. Install the side engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
  22. Install the air filter housing. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  23. Install the Mass Airflow (MAF) sensor. Refer to SENSOR, MASS AIRFLOW (MAF), REMOVAL AND INSTALLATION .
  24. Install the engine belly pan. Refer to BELLY PAN, ENGINE, REMOVAL AND INSTALLATION .
  25. Install the top engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
  26. Fill the turbocharger cooling system. Refer to DRAINING AND FILLING THE TURBOCHARGER COOLING SYSTEM .
  27. Connect the negative battery cable.
  28. Remove the support and lower the vehicle.
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