Intake Manifold: Service and Repair

REMOVAL
1. Relieve fuel pressure. See Powertrain Management.
2. Negative (-) battery cable.
3. Drain engine coolant. See Cooling System.
4. Air cleaner (ACL). See Powertrain Management.
5. The following electrical connectors:
- Engine Coolant Temperature (ECT) sensor connector.
- Coolant temperature sending unit connector.
- Throttle Position (TP) Sensor electrical connector.
- Exhaust gas recirculation solenoid vacuum valve.
- Idle Air Control (IAC) valve or Idle Speed Control (ISC) motor electrical connector.
- Ground wires from intake manifold.
- Heated Oxygen Sensor (H02S1) electrical connector.
- Throttle Body Fuel Injection (TBI) unit electrical connector.
- Manifold Absolute Pressure (MAP) Sensor electrical connector.
- Oil pressure switch electrical connector.
- Early Fuel Evaporation (EFE) heater electrical connector (if equipped).
- Generator electrical connectors.
- Starter solenoid electrical connectors.
- Release wiring harness from retaining clamps.





6. Fuel return and fuel feed hoses from TBI unit.





7. Coolant hoses from TBI unit and intake manifold.
8. The following vacuum hoses:
- EVAP canister hose from EVAP canister pipe.
- Manifold absolute pressure sensor hose from intake manifold or throttle body (TB).
- Brake booster hose from intake manifold.
- IAC valve hose from TBI unit.
9. Positive Crankcase Ventilation (PCV) hose from cylinder head cover.
10. Accelerator cable from TBI unit.





11. Five nuts, two bolts and intake manifold with TBI unit and wire clamps from cylinder head.
12. Intake manifold gasket from cylinder head.

INSTALLATION
1. New intake manifold gasket to cylinder head.
2. Intake manifold with TBI unit and wire clamps to cylinder head; secure with five nuts and two bolts.
3. PCV hose to cylinder head cover.

Vacuum Hose Connections And Routing:

4. The following vacuum hoses:
- EVAP canisters.
- Manifold absolute pressure sensor hose to intake manifold or TB.
- Brake booster hose to intake manifold.
- IAC valve hose to TBI unit.
5. Coolant hoses to TBI unit and intake manifold.
6. Fuel return and fuel feed hoses to TBI unit.
7. The following electrical connectors:
- ECT sensor electrical connector.
- Coolant temperature sending unit connector.
- EFE heater electrical connector (if equipped).
- ECT switch electrical connector.
- TP sensor electrical connector.
- EGR solenoid vacuum valve electrical connector.
- IAC valve or ISC motor electrical connector.
- Ground wires to intake manifold.
- H02S 1 electrical connector.
- TBI unit electrical connector.
- MAP sensor electrical connector.
- Oil pressure switch electrical connector.
- Generator electrical connectors.
- Starter solenoid electrical connectors.
8. Secure wiring harness to retaining clamps.
9. Accelerator cable to TBI unit. Adjust accelerator cable play to specifications. See Powertrain Management.
10. ACL to TBI unit. See Powertrain Management.
11. Negative (-) battery cable.
12. Refill cooling system. See Cooling System.
13. Upon completion of installation, start engine and check for fuel leaks and engine coolant leaks.