Intake Manifold: Service and Repair

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 cleaner assembly.
3. Disconnect Intake Air Temperature (IAT) sensor electrical connection.
4. Disconnect crankcase vent hose from camshaft cover.
5. Remove air inlet hose.
6. Disconnect electric connections:
6.1 Idle Air Control (IAC)
6.2 Throttle Position Sensor (TPS)
6.3 Manifold Absolute Pressure (MAP)




7. Remove engine harness from top of manifold and disconnect harness from under intake manifold.
8. Remove fuel pressure regulator vacuum pipe.
9. Disconnect EVAP purge solenoid hose from throttle body.

CAUTION: DO NOT BEND THROTTLE CABLE OR TRANS DOWNSHIFT CABLE (AUTO TRANS ONLY).

10. Unclip throttle cable, trans downshift cable (auto trans only), and brake booster pipe retaining clips.
11. Remove throttle cable and trans downshift cable (auto trans only) from throttle body linkage cam.
12. Disconnect brake booster vacuum pipe at brake booster.




13. Remove oil level indicator tube.
14. Remove throttle body bolts and nuts. Secure throttle cable bracket away from engine.
15. Remove throttle body.




16. Remove intake manifold bolts and nuts.
17. Remove intake manifold and gasket assembly.

INSTALLATION

NOTE: The intake manifold gasket assembly may be reused if the seal rings are not damaged.




1. Install intake manifold gasket assembly.
2. Install intake manifold onto cylinder head.
3. Install intake manifold bolts and nuts.

Torque:
Intake Manifold-to-Cylinder Head Bolts: 10 N.m (89 in-lbs)

Torque:
Intake Manifold-to-Cylinder Head Nuts: 10 N.m (89 in-lbs)

NOTE: The throttle body seal ring may be reused if not damaged or cut.




4. Install throttle body seal ring into seal ring groove.
5. Install throttle body onto intake manifold.
6. Install throttle cable bracket onto throttle body studs.
7. Install throttle body nuts and bolts.

Torque:
Throttle Body Bolts: 10 N.m (89 in-lbs)

Torque:
Throttle Body Nuts: 10 N.m (89 in-lbs)

8. Install oil level indicator tube and tube fastener.

Torque:
Oil Level Indicator Tube-to-Intake Manifold Bolt: 10 N.m (89 in-lbs)




9. Connect brake booster vacuum pipe at brake booster.

CAUTION: DO NOT BEND THROTTLE CABLE OR TRANS DOWNSHIFT CABLE (AUTO TRANS ONLY).

10. Install throttle cable, trans downshift cable (auto trans only), and brake booster pipe into retaining clips.
11. Connect throttle cable and trans downshift cable (auto trans only) to throttle body linkage cam.
12. Connect EVAP purge solenoid hose to throttle body.




13. Install and connect fuel pressure regulator vacuum pipe to throttle body and regulator.
14. Route engine wire harness on top of engine and connect additional harness clips under intake manifold.
15. Install harness bracket bolts.

Torque:
Engine Harness Bracket Bolts: 10 N.m (89 in-lbs)

16. Connect electrical connections:
16.1 Manifold Absolute Pressure (MAP)
16.2 Throttle Position Sensor (TPS)
16.3 Idle Air Control (IAC)




17. Install air inlet hose to throttle body.
18. Connect crankcase vent hose to camshaft cover.
19. Connect intake air temperature (IAT) electrical connection.
20. Install air cleaner assembly.
21. Connect the negative battery cable.