Intake Manifold: Service and Repair
Removal1. Disconnect the battery ground cable.
2. Drain the engine cooling system.
3. Remove the air cleaner outlet tube.
4. Disconnect the fuel line.
5. Remove the wiper arm and pivot shaft.
6. Remove the drive belt.
7. Raise the vehicle on a hoist.
8. Disconnect the electrical connector at the crankshaft position (CKP) sensor.
^ Disconnect the pin-type retainer from the A/C compressor bracket.
9. Disconnect the electrical connector from the A/C compressor.
10. Remove the oil bypass filter.
11. Disconnect the oil pressure sensor electrical connector and the power steering pressure (PSP) switch electrical connector.
12. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
13. Lower the vehicle.
14. Disconnect the two differential pressure feedback EGR hoses.
15. Disconnect the RH heated oxygen sensor electrical connector.
16. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.
17. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.
18. Disconnect the accelerator cable and the speed control actuator cable.
19. Remove the cables from the EGR tube heat shield and position out of the way.
20. Remove the bolts and the EGR tube heat shield.
21. Disconnect the evaporative emissions (EVAP) return tube, the main chassis vacuum supply line, and the EGR valve vacuum supply.
22. Disconnect the positive crankcase ventilation (PCV) tube assembly at two locations and remove.
23. Disconnect the electrical connector from the EGR vacuum regulator solenoid.
24. Disconnect the vacuum line from the EVAP canister purge valve.
25. Disconnect the generator cable and electrical connector.
26. Remove the bolts and the generator mounting bracket.
27. Remove the upper radiator hose.
28. Disconnect the electrical connector from the idle air control (IAC) valve and the throttle position (TP) sensor.
29. Disconnect the heater water hose.
30. Disconnect the EGR tube from the EGR valve.
31. Note: The LH heated oxygen sensor and the transmission electrical connectors are attached to the wiring bracket and must be separated from the bracket.
Remove the wiring bracket.
^ Disconnect the wiring connectors.
^ Separate the transmission harness from the stud.
^ Remove the nut and the bolt and remove the bracket.
32. Remove the bolts and the throttle body.
33. Separate the fuel charging wiring pin-type retainer from the crash bracket.
34. Remove the bolt and the stud and remove the crash bucket.
35. Disconnect the vacuum lines and remove the vacuum harness.
36. Remove the studs and the fuel injection supply manifold and fuel injectors as an assembly.
37. Remove the bolts and the ignition coils.
38. Remove the bolts and the water outlet adapter.
39. Remove the water thermostat.
40. Remove the bolts and the intake manifold.
41. Remove the intake manifold gaskets.
42. Clean the sealing surfaces.
Installation
1. Install the new intake manifold gaskets.
2. Install the intake manifold and hand-tighten the bolts at the locations shown.
3. Install the ignition coils and tighten the bolts.
4. Install the fuel injection supply manifold and tighten the studs.
5. Install the crash bracket and loosely install the bolt and the stud.
6. Install the water thermostat.
7. Install the water outlet adapter and loosely install the bolts.
8. Tighten the bolts in sequence.
9. Tighten the stud.
10. Tighten the bolts.
11. Install the throttle body and tighten the bolts.
12. Install the wiring bracket.
^ Position the bracket.
^ Install the nut and the bolt.
^ Attach the wiring connectors to the wiring bracket.
^ Connect the LH heated oxygen sensor electrical connector.
13. Connect the EGR tube to the EGR valve.
14. Position the EGR tube heat shield and install the bolts.
15. Connect the heater water hose and position the clamp.
16. Connect the electrical connector to the:
^ IAC control valve.
^ TP sensor.
17. Install the upper radiator hose:
^ Install the upper radiator hose.
^ Position the clamps.
18. Connect the generator electrical connector and the battery lead.
19. Install the generator mounting bracket:
^ Position the generator mounting bracket.
^ Install the bolts.
20. Position the vacuum harness and connect the vacuum line to the EVAP canister purge valve.
21. Connect the electrical connector and the vacuum lines to the EGR vacuum regulator solenoid.
22. Install and connect the PCV tube.
23. Connect the vacuum lines for the EVAP canister purge valve, the main chassis vacuum supply line and the EGR valve.
24. Reposition and attach the cables to the EGR tube heat shield.
25. Connect the accelerator cable and the speed control actuator cable.
26. Connect the fuel charging wiring electrical connectors to the eight fuel injectors.
27. Connect the fuel charging wiring electrical connectors to the eight ignition coils.
28. Connect the RH heated oxygen sensor Electrical connector.
29. Connect the two differential pressure feedback EGR hoses.
30. Raise the vehicle.
31. Connect the EGR tube to the exhaust manifold
connector.
32. Connect the electrical connector to the oil pressure sensor and the PSP switch.
33. Install the oil bypass filter.
34. Connect the electrical connector to the A/C compressor.
35. Connect the electrical connector to the CKP sensor.
^ Connect the pin-type retainer to the A/C Compressor bracket.
36. Lower the vehicle.
37. Install the drive belt.
38. Install the wiper arm and pivot shaft.
39. Connect the fuel line.
40. Install the air cleaner outlet tube.
41. Connect the battery ground cable.
42. Check the engine oil.
43. Fill the engine cooling system.