Intake Manifold: Service and Repair

Intake manifold, removing and installing

Removing

Note: All tie wraps opened or cut during removal must be reinstalled at the same locations.

CAUTION! BEFORE disconnecting the battery:
- Stop the engine.
- Be sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM).
- Determine the correct coding for the anti-theft radio.




- Disconnect battery Ground (GND) strap.
- Remove engine covers.
- Drain coolant. Service and Repair




- Remove hose (arrow) for Leak Detection Pump (LDP) -Vl44-.




- Disconnect Accelerator Pedal (AP) cable from throttle valve control module -J338- and mounting flange (arrows) without removing positioning clip.
- Remove air guide hose -6- at throttle valve control module.
- Remove vacuum hose -1-.
- Disconnect vacuum line -3- to Evaporative Emissions (EVAP) canister.
- Disconnect vacuum hose -2- at brake servo.

Note: For vehicles with automatic transmission, remove vacuum hose -2from behind vacuum booster.

- Disconnect the following harness connectors:
4 - For Intake Air Temperature (IAT) sensor -G42-
5 - For throttle valve control module - J338-




- Disconnect harness connector from Camshaft Position (CMP) sensor G40- (arrow).




- Unbolt fuel supply rail retaining bolts and disconnect vacuum line at fuel pressure regulator (arrows).
- Disconnect fuel supply rail with injectors from intake manifold and lay aside in rear of engine compartment on clean cloth.
- Disconnect coolant hoses at upper coolant line.




- Disconnect upper coolant line at intake line and rear coolant flange at rear of cylinder head (arrows).




- Disconnect crankcase ventilation hose -1- at intake manifold.
- Remove intake manifold brace (arrows).
- Remove dipstick.
- Unbolt intake manifold at flange and remove.

Note: Stuff clean cloths into cylinder head intake ports.

Installing
Installation is the reverse of removal, noting the following:

Note: Replace gaskets and O-rings.

- Adjust Accelerator Pedal (AP) cable.
- Top up coolant.

CAUTION! Be sure the ignition is switched OFF. Failure to do so may damage the Engine Control Module (ECM).

- Switch ignition off and reconnect battery Ground (GND) strap.
- After connecting battery, enter anti-theft code for radio
- Radio operating manual
- Fully close power windows to stop.
- Operate all power window switches again for at least one second in "close" direction to activate "one touch" opening/closing function.
- Set clock to correct time.
- Perform throttle valve control module adaptation to Engine Control Module (ECM).

Tightening Torques