Intake Manifold: Service and Repair

Fig. 2 Removing Plenum And Fuel Rail:

Intake Manifold Tightening Sequence:

1. Remove air cleaner assembly, including air flow duct from throttle body, then disconnect battery ground cable.
2. Remove all cables at throttle body, then disconnect brake vacuum pipe at plenum.
3. Remove cable bracket at plenum, then all necessary vacuum lines.
4. Remove EGR valve, throttle body and ignition wire plastic shield bolts from plenum.
5. Remove plenum attaching bolts, then plenum, Fig. 2.
6. Remove fuel lines at fuel rail. Refer to MAINTENANCE PROCEDURE/RELIEVING FUEL SYSTEM PRESSURE for fuel pressure bleed procedure.
7. Remove serpentine drive belt, then alternator. Position alternator aside.
8. Remove power steering lines at alternator bracket, then power steering pump mounting bolts. Position pump aside.
9. Remove wiring from fuel injectors, then drain cooling system.
10. Remove bypass hose at water pump and cylinder head.
11. Remove PCV hose, then front valve cover.
12. Remove alternator brace and bracket, then rear valve cover.
13. Remove upper radiator hose, then all necessary wiring.
14. Remove coolant sensor, then fuel lines at bracket.
15. Remove throttle body heater hose, then heater pipe at intake.
16. Remove intake manifold attaching bolts, then intake manifold. Retain Bevelled washers in their same position on four center bolts.
17. Loosen rocker arms, then remove pushrods. Intake and exhaust pushrods are different lengths with exhaust pushrods being longer of the two.
18. Reverse procedure to install, noting the following:
a. Place 3 mm bead of suitable RTV sealer on each ridge where front and rear of intake manifold contacts the block.
b. Torque intake manifold attaching bolts to 15 ft. lbs. in sequence shown in Fig. 3, then retighten to 24 ft. lbs. in sequence shown in Fig. 3.
c. Torque all bolts/nuts to specifications.