Intake Manifold: Service and Repair

Fig. 3 Intake Manifold Tightening Sequence:

NON-TURBOCHARGER MODELS
1. Disconnect battery ground cable.
2. Remove air cleaner duct from manifold.
3. Remove direct ignition unit, then drain engine coolant.
4. Disconnect coolant and vacuum hoses from manifold.
5. Remove throttle body, gasket, fuel injectors and fuel rail.
6. Remove EGR and PCV hose from manifold.
7. Remove generator and generator bracket at camshaft carrier.
8. Remove power steering bracket from intake manifold, then set power steering and bracket assembly aside.
9. Remove ECM harness to gain access to intake manifold lower retaining nuts.
10. Remove intake manifold attaching nuts, then the manifold.
11. Reverse procedure to install, using sequence shown in Fig. 3 tighten manifold attaching nuts to specification.

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.