Intake Manifold: Service and Repair

1. Disconnect battery ground cable.
2. Drain cooling system.
3. Remove engine appearance cover, air cleaner outlet tube and air intake resonator.
4. Relieve fuel system pressure.
5. Remove wiper module and air inlet tube.
6. Release belt tensioner and remove accessory drive belt.
7. Disconnect ignition plug wires from spark plugs. Do not pull on wires.
8. Disconnect ignition wire brackets from valve cover studs.
9. Disconnect both ignition coils, CID sensor and ignition wires from both coils.
10. Remove ignition wire tray and ignition wire assembly.
11. Disconnect alternator wiring harness from junction block, fender apron and alternator.
12. Disconnect upper radiator hose and water bypass tube to the thermostat hose at the water bypass tube.
13. Disconnect electrical connectors at ECT and engine temperature sending unit at bottom of coolant bypass tube.
14. Remove coolant bypass tube
15. Remove alternator and mounting bracket.
16. Disconnect accelerator cable and speed control actuator from throttle body.
17. Disconnect the following vacuum lines:
a. Chassis vacuum supply hose.
b. Fuel pressure regulator vacuum harness.
c. Righthand and lefthand intake manifold runner controls (IMRC).
d. Intake manifold connection.
e. Crankcase vent.
f. Throttle body.
g. PCV.
18. Disconnect and remove upper engine wiring harness from intake manifold.
19. Disconnect eight fuel injector connectors.
20. Remove EGR valve.
21. Disconnect IAC and TPS electrical connectors.

Fig. 7 Intake Manifold Bolt Removal Sequence:

22. Loosen and remove 20 intake manifold to cylinder head retaining bolts and studs in sequence shown.
23. Remove upper intake manifold.
24. Disconnect oil sending unit and EVO sensor, then position aside.
25. Disconnect EGR tube from right exhaust manifold, then lower vehicle.
26. Disconnect 42-pin connector, A/C compressor, HDR sensor and canister purge solenoid.
27. Remove PCV valve from valve cover, then disconnect canister purge vent hose from PCV valve.
28. Disconnect accelerator and speed control cables from throttle body, then remove accelerator cable bracket from intake manifold and position aside.
29. Disconnect throttle valve cable from throttle body.
30. Disconnect vacuum hose from throttle body adapter port.
31. Disconnect both HEGO sensors and heater supply hose.
32. Remove thermostat housing, then disconnect upper hose and position aside.
33. Remove bolts attaching intake manifold, then the intake manifold and gaskets.
34. Reverse procedure to install, noting the following:
a. Clean cylinder head and intake manifold surfaces.
b. Install new intake manifold gaskets.

Fig. 9 Intake Manifold Tightening Sequence:

c. Following sequence, tighten fasteners 5,7,9,11 to 9-11 ft lb. Tighten the rest to 13-16 ft lb. Rotate all fasteners an additional 85-95°.

Fig. 10 Intake Manifold Runner Control (IMRC) Fastener Locations.:

d. Tighten 4 intake manifold runner control (IMRC) bolts to 71-89 in lb in sequence, then an additional 85-95°.