Intake Manifold: Service and Repair

Fig. 4 Intake Manifold & Plenum:

1. Relieve fuel system pressure. Refer to MAINTENANCE PROCEDURES/FUEL PRESSURE RELIEF.
2. Disconnect battery ground cable, then drain cooling system.
3. Remove water hose from bottom of intake manifold.
4. Remove intake plenum, Fig. 4.
5. Disconnect EGR pipe and tag, remove wiring, then hoses that may interfere with manifold removal.
6. Remove intake manifold attaching bolts and nuts.
7. Remove intake manifold bracket, then the intake manifold, Fig. 4.
8. Clean cylinder head and intake manifold mating surfaces.
9. Install new intake manifold gasket.
10. Install intake manifold, attaching nuts and bolts.
11. Install intake plenum.
12. Install intake manifold bracket, then tighten to specifications.
13. Install remaining components in reverse order.