Intake Manifold Replacement
TOOLS REQUIRED- SA9127E Gauge Bar Kit
- J 37088-1A Fuel Line Separator
- J 37088-2A Fuel Line Separator
REMOVAL
NOTE: Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold is made of a composite plastic and can be damaged if it is removed when the engine is hot.
1. Disconnect the negative battery cable.
2. Remove air inlet tube and air cleaner assembly.
3. Relieve fuel system pressure. Refer to "Fuel System Pressure Relief" procedure. Service and Repair
4. Disconnect fuel lines (supply and return) from the fuel rail using special tool (J 37088 - 1A and 2A).
5. Disconnect Throttle Position Sensor (TPS) and Idle Air Control (IAC) electrical connectors.
6. Disconnect Manifold Air Pressure (MAP) sensor electrical connection.
7. Disconnect throttle and cruise control cables.
8. Remove throttle body.
9. Remove fuel rail assembly.
10. Remove intake manifold retaining nuts and bolts.
11. Remove intake manifold.
12. Remove intake manifold gasket. The gasket is reusable if it is not damaged.
13. If intake manifold needs to be replaced, transfer the following parts:
- throttle body
- throttle body gasket. The manifold-to-throttle body gasket is reusable if it is not damaged.
INSTALLATION
1. Install intake manifold studs in the manifold face.
Torque: 6 N.m (60 in-lbs)
2. Install a new intake manifold gasket on intake manifold.
3. Install intake manifold.
4. Install intake manifold bolts and nuts. Tighten bolts starting with center bolts and work out evenly.
Torque: 10 N.m (89 in-lbs)
5. Install fuel rail assembly.
6. Install fuel rail stud.
Torque: 10 N.m (89 in-lbs)
7. Install new throttle body studs if necessary.
Torque: 6 N.m (60 in-lbs)
8. Install throttle body.
Torque: 10 N.m (89 in-lbs)
9. Install pressure regulator vacuum hose.
10. Connect throttle and cruise control cables.
11. Connect Manifold Air Pressure (MAP) sensor electrical connection.
12. Connect Throttle Position Sensor (TPS) and Idle Air Control (IAC) electrical connectors.
13. Connect fuel lines (supply and return) to fuel rail.
14. Install air inlet tube and air cleaner assembly.
15. Connect the negative battery cable.