Intake Manifold: Service and Repair

1. Release fuel system pressure as outlined in Technician Safety Information, then disconnect battery ground cable.
2. Remove timing belt as outlined in "Timing Belt, Replace".
3. Drain engine coolant, then remove distributor and ignition wires.
4. Separate control wires from intake manifold collector, then remove idle air control valve/auxiliary air control valve, throttle position sensor and closed throttle position switch connectors.
5. Remove air cut valve water, PCV, vacuum gallery, swirl control valve, master cylinder and EGR valve vacuum hoses, then the EGR flare tube.

Fig. 2 Upper Intake Manifold Collector Bolt Tightening Sequence:

6. Remove upper intake manifold collector, loosening bolts in reverse tightening order, Fig. 2.

Fig. 3 Lower Intake Manifold Collector Bolt Loosening Sequence:

7. Remove lower intake manifold collector, Fig. 3.
8. Disconnect injector, coolant temperature switch, coolant temperature sensor, power valve control solenoid valve, EGRC solenoid valve and EGR temperature sensor harness connectors.
9. Disconnect vacuum gallery, then the pressure regulator valve and all hoses connected with vacuum gallery.
10. Disconnect heater hose from rear of engine, fuel feed and return hoses, and injector fuel tube assembly.

Fig. 4 Intake Manifold Bolt Tightening Sequence:

11. Remove intake manifold bolts in reverse order of tightening, Fig. 4, then intake manifold.
12. Reverse procedure to install, tightening bolts to specifications.