Intake Manifold: Service and Repair

Intake Manifold Removal and Installation
Exploded View





NOTE: Use new O-rings and gasket when reassembling.

Removal
1. Turn off the manual shut-off valve.
2. To reduce pressure in the lines, start the engine and run it until it stalls.
3. Make sure you have the anti-theft code for the radio, then write down the customer's radio station presets.
4. Disconnect the negative cable from the battery.
5. Loosen the drain plug in the radiator, drain the engine coolant.
6. Remove the throttle cable and cruise control actuator cable.
7. Remove the intake resonator.
8. Remove the air cleaner housing.





9. Remove the water bypass hoses.





10. Disconnect the brake booster vacuum hose (A) and water four way joint (B).
11. Remove the fuel injectors.





12. Remove fuel feed pipe A.





13. Disconnect the fuel feed hose.





14. Remove the air cleaner housing bracket.





15. Remove the thermo valve bolt (A) and intake manifold bracket bolt (B).





16. Remove the intake manifold.

Installation





1. Install the intake manifold (A) with a new gasket (B), then tighten the three nuts (C) and two bolts (D) by hand until they stop.





2. Tighten the nuts (A) 90 - 135°
3. Tighten the nut (B) and bolts (C).





4. Tighten the thermo valve bolt (A) and intake manifold bracket bolt (B).





5. Install the air cleaner housing bracket.





6. Connect the fuel feed hose with a new O-ring.





7. Install the fuel feed pipe A with new O-rings.
8. Install the fuel injectors.





9. Connect the brake booster vacuum hose (A) and water four way joint (B).





10. Connect the water bypass hoses.
11. Install the air cleaner housing.
12. Install the intake resonator.
13. Install the throttle cable.
14. Adjust the throttle cable.
15. Install the cruise control actuator cable.
16. Adjust the cruise control actuator cable.
17. Do the leak inspection.
18. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
19. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
20. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
21. Set the clock.
22. Do the powertrain control module (PCM) idle learn procedure.