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).
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 ECM. Refer to Engine Control Module Replacement (Service and Repair).





Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution).

6. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
7. Disconnect the integral clip (3) from the wire harness bracket.




8. Remove the engine wire harness bracket bolt.
9. Remove the electrical harness and vacuum lines from the intake manifold.




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




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




12. Disconnect the vacuum brake booster hose at the intake manifold.
13. Remove the generator. Refer to Generator Replacement (With 4.2L Engine) (Service and Repair)Generator Replacement (With V8 Engine) (Service and Repair).





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

14. Loosen the intake manifold bolts.
15. 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.

Tighten the intake manifold bolts to 10 Nm (89 lb in).

3. Install the generator. Refer to Generator Replacement (With 4.2L Engine) (Service and Repair)Generator Replacement (With V8 Engine) (Service and Repair).




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 (Specifications) for the correct part number.
6. Install the crankcase ventilation hose.




7. Connect the MAP sensor electrical connector.
8. Install the electrical harness and vacuum lines to the intake manifold.




9. Install the engine electrical harness bracket bolt.

Tighten the bolt to 10 Nm (89 lb in).




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




12. Install the PCM mounting studs (5) to the intake manifold.

Tighten the studs to 6 Nm (53 lb in).

13. Install the PCM (1) onto the studs (5).
14. Install the PCM retaining bolts (3).

Tighten the bolts to 8 Nm (71 lb in).

15. Install the PCM retaining nuts (6).

Tighten the nuts to 8 Nm (71 lb in).

16. Install the PCM harness connectors (2) to the PCM body.
17. Tighten the PCM harness connector retaining bolts (4).

Tighten the bolts to 8 Nm (71 lb in).

18. Install the throttle body. Refer to Throttle Body Assembly Replacement (Removal and Replacement).
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
20. 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.