Intake Manifold: Service and Repair

Fig. 2 Intake Manifold Replacement & Nut & Bolt Tightening Sequence:

1. Relieve fuel system pressure as follows:
a. Remove fuel pump fuse from fuse panel.
b. Start engine. After engine stalls, crank for ten seconds to relieve residual pressure from fuel system.
c. Turn ignition off and install fuel pump fuse.
2. Disconnect battery ground cable.
3. Remove air cleaner assembly, then drain cooling system.
4. Unfasten alternator and position aside.
5. Disconnect throttle cable from intake manifold bracket.
6. Disconnect throttle and throttle valve cables from throttle body.
7. Disconnect electrical connectors from throttle body.
8. Disconnect fuel inlet and return lines, then the coolant hoses from intake manifold. Place shop towel over fuel line and fitting when disconnecting.
9. Remove manifold attaching bolts and the manifold, Fig. 2.
10. Reverse procedure to install. Clean manifold and cylinder head mating surfaces and install a new gasket prior to installation. Tighten intake manifold attaching nuts and bolts in sequence shown in Fig. 2.