Intake Manifold: Service and Repair

Removal Procedure
1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the air cleaner assembly.





5. Disconnect the following electrical connectors:
^ The ground wires from the intake manifold
^ The fuel injector connectors
^ The Manifold Absolute Pressure (MAP) sensor connector
^ Throttle Position (TP) Sensor
^ Idle Air Control (IAC) Valve
^ EVAP Canister Purge Valve
6. Disconnect the wiring harness from the retaining clamps.
7. Remove the fuel return and the fuel feed hoses from the fuel rail.
8. Remove the coolant hoses from the throttle body (8) and intake manifold.
9. Remove the following hoses:
^ The canister purge hose from the intake manifold
^ The brake booster hose from the intake manifold
10. Remove the accelerator cable from the throttle body.
11. Remove the seven nuts and three bolts from the intake manifold.
12. Remove the intake manifold (6) with the throttle body (8) and the wire clamps from the cylinder head still attached.
13. Remove the intake manifold gasket from the cylinder head.

Installation Procedure





1. Install the new intake manifold gasket to the cylinder head.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the intake manifold with the TBI unit (8) and wire clamps to the cylinder head still attached.
Secure the intake manifold with the two nuts and the seven bolts.
Tighten the intake manifold mounting bolts and nuts to 23 Nm (17 ft. lbs.).
3. Install the following vacuum hoses:
^ The canister purge hose to the intake manifold
^ The brake booster hose from the intake manifold
4. Install the coolant hoses to the throttle body and the intake manifold.
5. Install the fuel return and the fuel feed hoses to the fuel rail.
6. Connect the following electric connectors:
^ The ground wires from the intake manifold
^ The fuel injector connector
^ The manifold absolute pressure (MAP) sensor connector
^ Throttle Position (TP) Sensor
^ Idle Air Control (IAC) Valve EVAP Canister Purge Valve
7. Secure the wiring harness to the retaining clamps.
8. Install the accelerator cable to the throttle body.
9. Adjust the accelerator cable play to the specifications. Refer to Accelerator Cable Replacement in Powertrain Management.
10. Install the air cleaner assembly to the throttle body.
11. Reconnect the negative battery cable.
12. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
13. Upon completion of the installation, start the engine and check for fuel and engine coolant leaks.