Intake Manifold: Service and Repair

Intake Manifold Replacement

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
2. Relieve the fuel pressure. Refer to Fuel Pressure Relief (Without CH-48027) (Fuel Pressure Relief (Without CH-48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)).
3. Remove the throttle body. Refer to Throttle Body Assembly Replacement (Removal and Replacement).




4. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).
5. Remove the PCM mounting studs (5) and position the PCM out of the way.




6. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).





Caution: Refer to Fastener Caution (Fastener Caution).

7. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
8. Disconnect the integral clip (3) from the wire harness bracket.




9. Remove the engine wire harness bracket bolt.
10. Position the engine electrical wire harness bracket with wires attached out of the way.




11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.




12. Disconnect the crankcase ventilation hose from the intake manifold.




13. Disconnect the vacuum brake booster hose at the intake manifold.
14. Remove the generator. Refer to Generator Replacement (With 4.2L Engine) (Generator Replacement)Generator Replacement (5.3L Engine) (Generator Replacement).





Note: The intake manifold bolts are captured within the intake manifold. Do not attempt to remove the bolts from the intake manifold.

15. Loosen the intake manifold bolts.
16. Remove the intake manifold.

Installation Procedure

1. Install a new intake manifold gasket to the intake manifold.





Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the intake manifold onto the engine and secure the manifold with the bolts and tighten to 10 Nm (89 in. lbs.).
3. Install the generator. Refer to Generator Replacement (With 4.2L Engine) (Generator Replacement)Generator Replacement (5.3L Engine) (Generator Replacement).




4. Install the vacuum brake booster hose to the intake manifold.




5. Lubricate the inner diameter of the crankcase ventilation hose. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.
6. Install the crankcase ventilation hose.




7. Connect the MAP sensor electrical connector.
8. Properly position the engine electrical harness bracket to the intake manifold.




9. Install the engine electrical harness bracket bolt and tighten to 10 Nm (89 in. lbs.).




10. Connect the integral clip (3) to the wire harness bracket.
11. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




12. Connect the ECT sensor electrical connector (1).




13. Install the PCM mounting studs (5) to the intake manifold and tighten to 6 Nm (53 in. lbs.).
14. Install the PCM (1) onto the studs (5).
15. Install the PCM retaining bolts (3) and tighten to 8 Nm (71 in. lbs.).
16. Install the PCM retaining nuts (6) 8 Nm (71 in. lbs.).
17. Install the throttle body. Refer to Throttle Body Assembly Replacement (Removal and Replacement).
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
19. Inspect for leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition, for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.