Intake Manifold: Service and Repair

1. Drain cooling system.
2. Remove air cleaner assembly.
3. Disconnect accelerator cable at throttle body. Disconnect speed control cable.
4. Disconnect transaxle linkage at upper intake manifold, then remove accelerator cable mounting bracket attaching bolts and position cables aside.
5. Disconnect thermactor air supply hose from check valve.
6. Disconnect flexible fuel lines from steel lines over rocker cover, then the fuel lines at injector fuel rail assembly.
7. Disconnect upper radiator hose from thermostat housing, then the coolant bypass hose.
8. Disconnect heater tube from intake manifold, then remove tube support bracket attaching nut. Remove heater hose from rear of tube, then loosen hose clamp at heater elbow and remove tube with hose and fuel lines attached and set aside.
9. Disconnect vacuum lines and all necessary electrical connectors.
10. Remove A/C compressor support bracket.
11. Disconnect PCV lines from upper intake manifold and lefthand rocker cover, then remove throttle body assembly.
12. Remove EGR valve assembly from upper manifold.
13. Remove wiring retainer bracket and position aside.

Fig. 2 Upper Intake Manifold Replacement:

14. Remove upper intake manifold attaching bolts, then the manifold.
15. Remove fuel injectors and fuel rail assembly.
16. Remove heater outlet hose.
17. Remove lower manifold attaching bolts, the then lower manifold.

NOTE: It may be necessary to pry on front of lower manifold to break the seal. Do not damage sealing surfaces.

18. Reverse procedure to install, noting the following:
a. Apply a 1/8 inch bead of silicone at each corner where cylinder head meets the block.

Fig. 3 Intake Manifold Tightening Sequence:

b. Using sequence shown, torque manifold bolts in three steps. First step is to 7 ft lb, second step to 15 ft lb, third step to 24 ft lb.
c. Tighten throttle body bolts to 15-22 ft lb in a cross pattern.
d. Torque EGR attaching bolts to 15-22 ft lb.