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 assembly. See Powertrain Management.
5. The following electric connectors:
- Coolant temperature sensor connector.
- EGR solenoid vacuum valve.
- EGR by-pass valve.
- Idle Speed Control (ISC) solenoid valve connector.
- Ground wires from intake manifold.
- Oxygen sensor connector.
- Fuel injector connector.
- Manifold Absolute Pressure (MAP) sensor connector.
- Power Steering (P/S) pump pressure switch connector (if equipped).
- Oil pressure switch connector.
- Generator connectors.
- Starter solenoid connectors.
6. Release wiring harness from retaining clamps.
7. Fuel return and fuel feed hoses from throttle body.





8. Coolant hoses from throttle body and intake manifold (Figure 13).
9. The following vacuum hoses:
- Canister purge hose from intake manifold.
- Canister hose from canister pipe.
- Pressure sensor hose from intake.
- Brake booster hose from intake manifold.
- EGR modulator hoses from EGR valve.
- EGR solenoid vacuum valve.
10. PCV hose from cylinder head cover.
11. Accelerator cable from throttle body.
12. Seven nuts, three bolts and intake manifold with throttle body and wire clamps from cylinder head.
13. Intake manifold gasket from cylinder head.

INSTALLATION
1. New intake manifold gasket to cylinder head.
2. Intake manifold with throttle body to cylinder head and wire clamps to mounting bolts; secure with two nuts and seven bolts. Tighten intake manifold mounting bolts and nuts to 23 Nm (17 ft. lbs.).
3. PCV hose to cylinder head cover.
4. The following vacuum hoses:
- Canister purge hose to intake manifold.
- Canister hose from canister pipe.
- Pressure sensor hose from intake.
- Brake booster hose from intake manifold.
- EGR modulator hoses from EGR valve.
- EGR vacuum switching valve hose from valve.
5. Coolant hoses to throttle body and intake manifold.
6. Fuel return and fuel feed hoses to throttle body.
7. The following electric connectors:
- Coolant temperature sensor connector.
- EGR solenoid vacuum valve.
- EGR by-pass valve.
- ISC solenoid valve connector.
- Ground wires from intake manifold.
- Oxygen sensor connector.
- Fuel injector connector.
- MAP sensor connector.
- P/S pressure switch connector (if equipped).
- Oil pressure switch connector.
- Generator connectors.
- Starter solenoid connectors.
8. Secure wiring harness to retaining clamps.
9. Accelerator cable to throttle body. Adjust accelerator cable play to specifications. See Powertrain Management.
10. Air cleaner assembly to throttle body. 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.