Intake Manifold: Service and Repair

REMOVAL PROCEDURE





1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery cable.
4. Disconnect the Evaporative (EVAP) emission canister purge solenoid from the intake manifold and loosen the bracket bolt.
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 Manifold Absolute Pressure (MAP) sensor connector.
11. Disconnect the coolant hoses at the throttle body.
12. Disconnect the vacuum hoses as needed, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.
13. Disconnect the throttle cable from the throttle body and the intake manifold.
14. Remove the throttle cable bracket bolts from the intake manifold.
15. Remove the throttle cable bracket.
16. Remove the generator-to-intake manifold strap bracket bolts and the strap.





17. Remove the power steering hose clamp bolt, and position the hose clear of the repair area.
18. Remove the fuel rail and the injector cover as an assembly. Refer to Powertrain Management.





19. Remove the generator-to-intake manifold support bracket bolts.
20. Remove the generator-to-intake manifold support bracket.
21. Remove the intake manifold support bracket bolt at the engine block and the intake manifold.
22. Remove the intake manifold support bracket.





23. Remove the intake manifold retaining bolts and the nuts in the sequence shown.
24. Remove the intake manifold.
25. Remove the intake manifold gasket.
26. 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 bolts and the nuts in the sequence shown.
Tighten
Tighten the intake manifold retaining bolts and the nuts to 18 Nm (13 ft. lbs.).
4. Install the generator-to-intake manifold strap bracket and bolts.
Tighten
Tighten the generator-to-intake manifold strap bracket bolts to 20 Nm (15 ft. lbs.).
5. Install the intake manifold support bracket.





6. Install the intake manifold support bracket upper bolts to the intake manifold.
Tighten
Tighten the intake manifold support bracket upper bolts to 20 Nm (15 ft. lbs.).
7. Install the intake manifold support bracket lower bolt to the engine block.
Tighten
Tighten the intake manifold support bracket lower bolt to 20 Nm (15 ft. lbs.).
8. Install the generator-to-intake manifold support bracket and bolts.
Tighten
Tighten the generator-to-intake manifold support bracket bolts to 35 Nm (26 ft. lbs.).
9. Install the fuel rail and the injector cover as an assembly. Refer to Powertrain Management.





10. Install the throttle cable bracket.
11. Install the throttle cable bracket bolts.
Tighten
Tighten the throttle cable bracket bolts to 8 Nm (71 inch lbs.).
12. Connect the throttle cable to the intake manifold and the throttle body.
13. Connect all the previously disconnected vacuum lines.





14. Connect the Manifold Absolute Pressure (MAP) sensor connector.
15. Connect the coolant hoses to the throttle body.
16. Connect the Idle Air Control (IAC) valve connector.
17. Connect the Throttle Position Sensor (TPS) connector.
18. Position the power steering hose in place and install the clamp bolt.
Tighten
Tighten the power steering hose clamp bolt to 8 Nm (71 inch lbs.).
19. Connect the air intake tube to the throttle body.





20. Connect the IAT sensor connector.
21. Connect the EVAP emission canister purge solenoid at the intake manifold and tighten the bracket bolt.
Tighten
Tighten the canister purge solenoid bracket bolt to 5 Nm (44 inch lbs.).
22. Install the fuel pump fuse.
23. Connect the negative battery cable.
24. Refill the engine cooling system. Refer to Cooling System.