Intake Manifold: Service and Repair

REMOVAL
1. Perform the fuel system pressure release and fuel rail purge procedure, before attempting any repairs.
2. Disconnect the battery.





3. Disconnect the intake air temperature sensor electrical connector from air cleaner. Remove the throttle body hoses and air cleaner assembly (Fig. 9).





4. Remove the throttle cable (Fig. 10).
5. Disconnect the Crankcase Ventilation (CCV) and canister purge hoses.





6. Disconnect the throttle position sensor (TPS) electrical connector from intake manifold (Fig. 11).





7. Remove the brake booster hose from air intake plenum (Fig. 12).





8. Disconnect the Idle Air Control (IAC) motor electrical and hose connection (Fig. 13).
9. Remove the cowl cover.





10. Disconnect the electrical connectors at the ignition coils (Fig. 14).
11. Disconnect the two electrical connectors on the left rear plenum (Fig. 12).





12. Remove the fuel hose quick connect fitting from the fuel line. Use an open-end wrench to push in on the plastic ring located on the end of the fitting. Gently pull the fitting from the fuel rail (Fig. 15).

WARNING: WRAP A SHOP TOWEL AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.

13. Remove the intake manifold bolts. Lift the front of intake manifold and pull forward to remove.
14. Cover the intake manifold with suitable cover when servicing.

INSPECTION
1. Inspect manifold for cracks or other damage.
2. Inspect manifold sealing surfaces for damage.

INSTALLATION

CAUTION: When cleaning the cylinder head and block mating surfaces, do not use a metal scraper because the surfaces could be cut or ground. Instead, use a wooden or plastic scraper.

1. Remove covering on intake manifold and clean surface.
2. Clean all surfaces of cylinder block and cylinder heads.





NOTE: Be sure that the CCV hose is installed into the grommet before installing intake manifold (Fig. 16).





3. Carefully install the intake manifold gaskets (Fig. 17).





4. Set the intake manifold in position on the engine. Install intake manifold bolts and tighten initially to 1 Nm (10 in. lbs.). Then tighten bolts to 11 Nm (95 in. lbs.) in sequence shown in (Fig. 18).
5. Connect the fuel supply hose to chassis fuel tube assembly. Pull backward on the quick connect fitting to ensure complete insertion (Fig. 15).
6. Connect Idle Air Control (IAC) electrical and hose connectors.
7. Connect the CCV and canister purge hoses to intake plenum.
8. Connect the brake booster hose to intake plenum
9. Connect the ignition coils (Fig. 14) and the two electrical connectors at rear of engine (Fig. 12).
10. Install the cowl cover.
11. Connect the wiring connector to the throttle position sensor (TPS).
12. Install the throttle cable.
13. Install the air cleaner and throttle body hose assemblies. Connect intake air temperature sensor electrical connector to air cleaner assembly (Fig. 9).
14. Connect the battery.
15. With the DRB III Scan Tool, use the ASD Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.