Intake Manifold: Service and Repair

Fig. 3 Intake Manifold Tightening Sequence:

NON-TURBOCHARGED MODELS

1. Relieve fuel system pressure as outlined under MAINTENANCE PROCEDURE/RELIEVING FUEL SYSTEM PRESSURE procedure.
2. Disconnect battery ground cable.
3. Remove air cleaner, then drain cooling system.
4. Remove alternator and bracket at camshaft carrier.
5. Disconnect power steering pump and position aside.
6. Remove power steering bracket at intake manifold.
7. Remove ignition coil and bracket assembly, then the throttle cable from intake manifold bracket.
8. Remove throttle cable and TV cable from TBI unit.
9. Remove TBI unit electrical connector.
10. Remove vacuum brake hose, coolant hoses and fuel lines. Place shop towel over fuel line and fitting when disconnecting.
11. Remove ECM harness, then the intake manifold attaching nuts and manifold.
12. Reverse procedure to install. Refer to Fig. 3, for manifold nut tightening sequence.

TURBOCHARGED MODELS
1. Relieve fuel system pressure as outlined under MAINTENANCE PROCEDURE/RELIEVING FUEL SYSTEM PRESSURE procedure.
2. Remove induction tube and hoses.
3. Disconnect ignition coil, throttle body, MAP sensor and wastegate electrical connectors.
4. Remove PCV hose and throttle body vacuum hose.
5. Remove throttle cable and cruise control cable, if equipped.
6. Remove fuel line from throttle cable support bracket. Place shop towel over fuel line and fitting when disconnecting.
7. Remove ignition coil bracket attaching screws, then remove ignition coil bracket.
8. Remove vacuum hoses at rear of manifold.
9. Remove transmission filler tube bracket.
10. Remove manifold support bracket attaching bolts, then remove bracket.
11. Remove heater tube support bracket on lower side of manifold.
12. Disconnect fuel injector electrical connectors.
13. Remove coolant recovery tank and accessory drive belt.
14. Remove power steering and alternator front adjusting bracket.
15. Remove power steering pump bracket to engine head.
16. Remove fuel line to fuel rail inlet, then remove fuel return line from regulator outlet. Place shop towel over fuel line and fitting when disconnecting.
17. Remove intake manifold attaching nuts and washers, then remove manifold.
18. Reverse procedure to install. Torque intake manifold attaching bolts to specifications.