Intake Manifold: Service and Repair

Fig. 2 Disconnect Cables From Throttle Arm:

Fig. 10 Camshaft Identification:

REMOVAL

1. Disconnect battery ground cable.
2. Remove throttle body bonnet/air inlet hose from throttle body air cleaner.
3. Remove drive belt from power steering pump.
4. Unfasten power steering pump and position aside.
5. Remove power steering pump and brackets from water pump and intake manifold, then position aside.
6. Remove fuel tank filler cap to relieve pressure, then reinstall cap.
7. Disconnect black fuel supply line and gray return line from throttle body.
8. Disconnect accelerator cable from throttle body and hold-down bracket.
9. With finger pressure, disconnect cruise control connector from throttle body.
10. Unfasten electrical connectors for throttle position sensor, idle speed control motor, coolant temperature sensor from thermostat, coolant temperature sensor from intake manifold, fuel injector, air temperature sensor and oxygen sensor.
11. Disconnect crankcase ventilation vacuum hose and MAP sensor vacuum hose connector from throttle body.
12. Disconnect vacuum hose (76) from vacuum port (77) on the intake manifold, Fig. 2.
13. Disconnect vacuum hose from EGR transducer.
14. Disconnect vacuum hoses from EGR solenoid on driver's side of engine compartment.
15. Disconnect CCV hose from valve cover.
16. Remove molded vacuum harness.
17. Disconnect vacuum brake booster hose from intake manifold.
18. Loosen EGR tube nut from intake manifold and remove bolts securing EGR tube to exhaust manifold.
19. Install Mot. 453.01 clamps to heater hoses at front and rear of intake manifold.
20. Remove heater hose clamps and disconnect hoses from intake manifold.
21. Remove bolts (2, 3, 4 and 5) securing intake manifold to cylinder head Fig. 10., then loosen bolts (1, 6 and 7).
22. Remove intake manifold and gaskets, then drain coolant from manifold.

INSTALLATION

1. Clean intake manifold and cylinder head surfaces. Also clean EGR tube to exhaust manifold.
2. Install new intake manifold gasket over locating dowels, position in place and finger tighten mounting bolts.
3. Install new EGR tube gasket and finger tighten bolts (9 and 10) to exhaust manifold, leave EGR tube nut at the manifold finger tightened.
4. Tighten intake manifold bolts Fig. 10, in the following sequence:
a. Torque bolts 1, 6, 7 and 8 to 30 ft. lbs.
b. Torque bolts 2, 3, 4 and 5 to 23 ft. lbs.
c. Torque bolts 9 and 10 to 14 ft. lbs.
5. Refer to Removal procedure to complete installation.
6. Fill cooling system to proper level.