Intake Manifold: Service and Repair
Intake Manifold Removal and InstallationRemoval
1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery cable.
4. Disconnect the Charcoal Canister Purge (CCP) and Exhaust Gas Recirculation (EGR) solenoid from the intake manifold and loosen the bracket bolt.
5. Drain the engine coolant.
6. Disconnect the Manifold Air Temperature Sensor (MAT) connector.
7. Disconnect the air cleaner outlet hose from the throttle body.
8. Disconnect the Idle Air Control (IAC) valve connector.
9. Disconnect the Throttle Position Sensor (TPS) connector.
10. Disconnect the Manifold Absolute Pressure (MAP) sensor connector.
11. Disconnect the coolant hoses at the throttle body.
12. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.
13. Disconnect the throttle cable from the throttle body and the intake manifold.
14. Remove the throttle cable bracket bolts from the intake manifold.
15. Remove the throttle cable bracket.
16. Remove the generator-to-intake manifold strap bracket bolts and strap.
17. Remove the fuel rail as an assembly.
18. Remove the generator-to-intake manifold support bracket bolts.
19. Remove the generator-to-intake manifold support bracket.
20. Remove the intake manifold support bracket bolt at the engine block and the intake manifold.
21. Remove the intake manifold support bracket.
22. Remove the intake manifold retaining bolt and nuts in the sequence shown.
23. Remove the intake manifold.
24. Remove the intake manifold gasket.
25. Clean the sealing surfaces of the intake manifold and the cylinder head.
Installation
1. Install the intake manifold gasket.
2. Install the intake manifold.
3. Install the intake manifold retaining bolt and nuts in the sequence shown.
Tighten: Tighten the intake manifold retaining bolt and nuts to 22 Nm (16 ft. lbs.).
4. Install the generator-to-intake manifold strap bracket and bolts.
Tighten: Tighten the generator-to-intake manifold strap bracket bolts to 22 Nm (16 ft. lbs.).
5. Install the intake manifold support bracket.
6. Install the intake manifold support bracket upper bolts to the intake manifold.
Tighten: Tighten the intake manifold support bracket upper bolts to the intake manifold to 25 Nm (18 ft. lbs.).
7. Install the intake manifold support bracket lower bolt to the engine block.
Tighten: Tighten the intake manifold support bracket lower bolt to the engine block to 25 Nm (18 ft. lbs.).
8. Install the generator-to-intake manifold support bracket and bolts.
Tighten: Tighten the generator-to-intake manifold support bracket bolts to 37 Nm (27 ft. lbs.).
9. Install the fuel rail and injector cover as an assembly.
10. Install the throttle cable bracket.
11. Install the throttle cable bracket bolts.
Tighten: Tighten the throttle cable bracket bolts to 8 Nm (71 inch lbs.).
12. Connect the throttle cable to the intake manifold and the throttle body.
13. Connect all of the necessary vacuum lines that were previously disconnected.
14. Connect the MAP sensor connector.
15. Connect the coolant hoses to the throttle body.
16. Connect the IAC valve connector.
17. Connect the TPS connector.
18. Connect the air cleaner outlet hose to the throttle body.
19. Connect the MAT sensor connector.
20. Connect the CCP and EGR solenoid at the intake manifold and tighten the bracket bolt.
Tighten: Tighten the charcoal canister purge and exhaust gas recirculation solenoid bracket bolt to 5 Nm (44 inch lbs.).
21. Install the fuel pump fuse.
22. Connect the negative battery cable.
23. Refill the engine cooling system.