Intake Manifold: Service and Repair

1. Release fuel system pressure as outlined under "Precautions".
2. Drain cooling system.
3. Remove engine cover from top of plenum.

Fig.2 Throttle Lever:

4. Remove accelerator cable and speed control cable from throttle arm.

Fig.3 Idle Air Control Motor,charge Air Temperature Sensor & MTV Component Location:

5. Disconnect electrical connector from idle air control motor and charge air temperature sensor then remove vacuum hose from Manifold Tuning Valve (MTV).
6. Remove ground screw from intake manifold.

Fig.4 Map Location:

7. Disconnect electrical connector from Manifold Absolute Pressure (MAP) sensor and Throttle Position Sensor (TPS).
8. Disconnect purge hose from throttle bodies.
9. Disconnect Positive Crankcase Ventilation (PCV) make up air hose and idle air control motor supply hose then remove the air inlet plenum from behind manifold.
10. Disconnect PCV, brake booster and remaining vacuum hoses from intake manifold.
11. Remove EGR tube mounting bolts at intake manifold plenum.
12. Remove air plenum support bracket on each side of manifold.

Fig.5 Intake Plenum Bolt Length Identification:

13. Remove intake manifold plenum mounting bolts. The plenum uses two different length bolts.
14. Remove intake manifold plenum.
15. Remove upper radiator hose from thermostat housing and heater hose from rear of intake manifold.

Lower Intake Manifold Tightening Sequence:

16. Remove intake manifold attaching bolts (in sequence shown) then the intake manifold.
17. Reverse procedure to install noting the following:
a. Bleed cooling system after refilling cooling system.
b. Torque intake manifold bolts, in sequence, to 20-21 ft-lbs.