Intake Manifold: Service and Repair

INTAKE MANIFOLD
Removal Procedure





1. Remove the fuel pump fuse.
2. Start the engine. Crank the engine for 10 seconds after it stalls to rid the fuel system of fuel pressure.
3. Disconnect the negative battery cable.
4. Disconnect the powertrain control module/engine control module (PCM/ECM) ground terminal from the intake manifold.
5. Drain the engine coolant. Refer to Cooling System.
6. Disconnect the intake air temperature (IAT) sensor connector.





7. Disconnect the air intake tube from the throttle body.





8. Disconnect the idle air control (IAC) valve connector.
9. Disconnect the throttle position sensor (TPS) connector.
10. Disconnect the coolant temperature sensor (CTS) connector.
11. Disconnect the engine coolant temperature (ECT) sensor connector.
12. Disconnect the heater inlet hose from the cylinder head.
13. Disconnect the surge tank coolant hose at the throttle body.
14. 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.
15. Disconnect the throttle cable from the throttle body and the intake manifold.
16. Remove the throttle cable bracket bolts from the intake manifold.





17. Remove the throttle cable bracket.
18. Remove the fuel injector rail and fuel injectors as an assembly. Refer to Powertrain Management.
19. Remove the generator. Refer to Starting and Charging.





20. Remove the intake manifold support bracket bolts and the intake manifold.
21. Remove the intake manifold support bracket.





22. Remove the intake manifold retaining nuts/bolts 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 Procedure
1. Install the intake manifold gasket.
2. Install the intake manifold.





3. Install the intake manifold retaining nuts/bolts in the sequence shown.
Tighten the intake manifold retaining nuts/bolts to 25 Nm (18 ft. lbs.)
4. Install the intake manifold support bracket.





5. Install the intake manifold support bracket upper bolts to the intake manifold.
Tighten the intake manifold support bracket upper bolts to 25 Nm (18 ft. lbs.).
6. Install the intake manifold support bracket lower bolt-to-engine block.
Tighten the intake manifold support bracket lower bolt-to-engine block to 40 Nm (30 ft. lbs.).
7. Install the generator. Refer to Starting and Charging.
8. Install the fuel rail and fuel injectors as an assembly. Refer to Powertrain Management.
9. Install the throttle cable bracket.





10. Install the throttle cable bracket bolts.
Tighten the throttle cable bracket bolts to 8 Nm (71 inch lbs.).
11. Connect the throttle cable to the intake manifold and the throttle body
12. Connect all of the necessary vacuum lines that were previously disconnected.
13. Connect the heater inlet hose to the cylinder head.
14. Connect the surge tank coolant hose to the throttle body.
15. Connect the CTS connector.
16. Connect the ECT sensor connector.





17. Connect the IAC valve connector.
18. Connect the TPS connector.





19. Connect the air intake tube to the throttle body.
20. Connect the IAT sensor connector.
21. Connect the PCM/ECM ground terminal to the intake manifold.
22. Install the fuel pump fuse.
23. Connect the negative battery cable.
24. Refill the engine cooling system. Refer to Cooling System.