Intake Manifold: Service and Repair

1. Relieve fuel system pressure as described under Engine/Service Precautions/Technician Safety Information/Fuel System Pressure Release.
2. Disconnect battery ground cable and drain cooling system.

Fig. 4 Throttle Cable Removal:

3. Remove air cleaner to throttle body hose, then disconnect throttle cable and transaxle kickdown linkage, Fig. 4.
4. Disconnect Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) electrical connectors from throttle body.
5. Disconnect vacuum hoses from throttle body.
6. Remove EGR tube flange from intake plenum.
7. Disconnect coolant temperature sensor and charge temperature sensor electrical connectors.
8. Disconnect air intake plenum vacuum connector, then disconnect fuel hoses from fuel rail.

Fig. 8 Air Intake Plenum To Intake Manifold Attaching Bolts:

Fig. 9 Removing Air Intake Plenum:

9. Remove air intake plenum to intake manifold attaching bolts, then air intake plenum.
10. Disconnect vacuum hoses from fuel rail and fuel pressure regulator, then disconnect fuel injector electrical connector from engine wiring harness.
11. Remove fuel pressure regulator attaching bolts, then loosen hose clamps and remove regulator from rail.
12. Remove fuel rail attaching bolts, then lift fuel rail assembly from intake manifold.
13. Disconnect radiator hose from thermostat housing and heater hose from heater pipe.
14. Remove intake manifold attaching bolts, then intake manifold.
15. Reverse procedure to install, noting following:
a. Discard gaskets and clean gasket surfaces on both manifolds and cylinder head.
b. Use a straightedge to ensure gasket surfaces on manifolds are flat and within .004-.008 inch per foot of manifold length.

Fig. 5 Intake Manifold Tightening Sequence:

c. Torque intake manifold bolts to 20 Nm (174 in. lbs.), in sequence shown in Fig. 5.
d. Tighten fuel rail attaching bolts to specifications.

Fig. 6 Intake Plenum Tightening Sequence:

e. Torque air intake plenum attaching bolts to 10-11 ft. lbs., in sequence shown in Fig. 6.