Intake Manifold: Service and Repair

Upper Intake Manifold:

REMOVAL

1. Remove intake air boot from throttle body and Mass Airflow Sensor.
2. Disconnect electrical connectors at Throttle Position Sensor, Air Bypass Valve, Vacuum Switching Valve and DIS Module.
3. Disconnect coolant bypass hoses and vacuum lines.
4. Disconnect EGR pipe from EGR Valve.
5. Remove eight bolts from intake manifold support brackets and remove brackets.
6. Remove bolt from coolant hose bracket.
7. Disconnect PCV hoses.
8. Remote twelve manifold retaining bolts.
9. Remove intake manifold and throttle body assembly.


INSTALLATION

1. Clean and inspect mounting surfaces.
2. Position new manifold gaskets.
3. Position manifold assembly, being careful not to pinch any hoses or wires.
4. Install twelve intake manifold bolts and tighten to 11-17 lb. ft. (15-23 N-m).
5. Connect PCV hoses.
6. Install manifold support brackets and coolant hose bracket. Tighten bolts to 11-17 lb. ft. (15-23 N-m)
7. Connect EGR pipe to EGR Valve.
8. Connect coolant bypass hoses and vacuum lines.
9. Connect electrical connectors at Throttle Position Sensor, Air Bypass Valve, Vacuum Switching Valve and DIS Module.
10. Install throttle cable and air intake boot.
11. Check and top off coolant.