Intake Manifold: Service and Repair

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INTAKE MANIFOLD REMOVAL / INSTALLATION - 2.3L

































Removal

1. Drain the engine cooling system. See - Removal and Replacement.

2. Remove the accelerator control splash shield.






3. Remove the air cleaner outlet pipe. See - Service and Repair.

4. Disconnect the throttle cables from the intake manifold.






a. Disconnect the accelerator cable and cruise control cable (if equipped) from the throttle linkage.

b. Disconnect the accelerator cable and cruise control cable (if equipped) from the mounting bracket.

5. Disconnect the throttle position (TP) sensor electrical connector.






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






7. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.






8. Disconnect the vapor purge tube quick connect coupling.

9. Disconnect the engine vacuum harness, brake booster hose and the crankcase breather hose. Disconnect the coolant hoses.






10. Disconnect two engine wiring harness pin-type retainers from the intake manifold.






11. Disconnect the pin-type retainer from the rear of the intake manifold.






12. Remove the exhaust gas recirculation (EGR) tube bracket bolt.






13. Remove the bolts from the EGR tube flange.






14. Detach the fuel supply tube and the electrical connectors from the bracket and disconnect the vapor purge tube quick connect coupling.






15. Disconnect the knock sensor (KS) electrical connector and disconnect the connector retainer from the intake manifold.

16. Remove the wiring harness pushpin from the bottom of the intake manifold.

17. Disconnect fuel supply tube from the manifold. See - Service and Repair.

18.

CAUTION:Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.Remove the 5 bolts and the intake manifold.






- Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging for the silicone gasket remover and metal surface prep.

19. Remove and discard the intake manifold gaskets.

Installation

1. Inspect and install new intake manifold gaskets.






2. Install the intake manifold and the five mounting bolts.






3. Connect the wiring pushpin to the bottom of the intake manifold.

4. Connect fuel supply tube to the manifold. See - Service and Repair.

5. Connect the engine KS connector to the intake manifold and connect the electrical connector.






6. Attach the electrical connectors and the fuel supply tube to the bracket and connect the vapor purge tube quick connect coupling.






7. Install the EGR flange mounting bolts.






8. Install the EGR tube bracket bolt.






9. Position the engine wiring harness and connect the pin-type retainers.






10. Connect the engine vacuum harness, brake booster hose and the crankcase breather hose. Connect the coolant hoses.






11. Connect the vapor purge hose and the IAC valve electrical connector.






12. Connect the MAP sensor electrical connector.






13. Connect the TP sensor electrical connector.






14. Connect the throttle cables to the intake manifold and the throttle body.






a. Connect the accelerator cable and cruise control cable (if equipped) into the mounting bracket.

b. Connect the accelerator cable and cruise control cable (if equipped) onto the throttle linkage.

15. Install the air cleaner outlet pipe. See - Service and Repair.

16. Install the accelerator control splash shield.






17. Fill and bleed the engine cooling system. See - Removal and Replacement.