Intake Manifold: Service and Repair

Intake Manifold

Removal
1. Disconnect the battery ground cable.
2. Drain the engine cooling system.
3. Remove the air cleaner outlet pipe-resonator assembly.
4. Disconnect the fuel spring lock coupling.
5. Remove the wiper mounting arm and pivot shaft.





6. Remove the RH cowl extension.
1 Remove the pin-type retainers.
2 Remove the nuts.
3 Remove the bolts.
4 Remove the extension.





7. Remove the LH cowl extension.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the extension.





8. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.





9. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.





10. Disconnect the accelerator cable, the speed control actuator cable, the throttle return spring and the cable retaining bolts.





11. Remove the cables from the exhaust gas recirculation (EGR) system module tube heat shield and position out of the way.





12. Remove the bolts and the EGR system module tube heat shield.





13. Disconnect the electrical connector and the vacuum hoses.





14. Disconnect the EVAP canister purge valve vacuum hose.





15. Disconnect the electrical connector and the harness location retainer.





16. Remove the bolts and the generator mounting bracket.





17. Disconnect the upper radiator hose.





18. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.





19. Disconnect the heater hose.





20. Disconnect the EGR system module tube nut from the EGR system module.





21. Remove the nut at the exhaust manifold and remove the EGR tube.





22. Separate the fuel charging wiring pin-type retainer from the crash bracket.





23. Remove the cables from the crash bracket.





24. Remove the crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.





25. Remove the stud.





26. Disconnect the fuel pressure sensor electrical connector and the vacuum hoses.





27. Remove the generator harness position retainer from the LH front stud.





28. Remove the fuel charging wiring pin-type retainer from the rear of the manifold.





29. Disconnect the ground wire connector from the RH rear stud.





30. Disconnect the coolant temperature sensor electrical connector.





31. Remove the bolts and the eight ignition coils.





32. Remove the bolts and the coolant outlet adapter.





33. Remove the thermostat and discard the O-ring.





34. Remove the bolts and the intake manifold.





35. Remove and discard the intake manifold gaskets.





36. Clean the sealing surfaces.

Installation

1. NOTE: Align the gasket locator tabs with the slots in the cylinder head.





Install 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 crash bracket and loosely install the bolt and the stud.





5. Tighten the bolts in the sequence shown.





6. Tighten the stud.





7. Connect the EGR system module tube to the EGR system module.





8. Install the EGR tube and nut at the exhaust manifold.





9. Position the EGR tube heat shield and install the bolts.





10. Connect the IAC control valve and the TP sensor electrical connectors.





11. Attach the cables to the crash bracket.





12. Install the generator mounting bracket and the bolts.





13. Connect the electrical connector and the harness location retainer.





14. Position the vacuum harness and connect the vacuum hose to the EVAP canister purge valve.





15. Connect the electrical connector and the vacuum hoses.





16. Connect the fuel pressure sensor electrical connector and the vacuum hoses.





17. Position and attach the cables to the EGR system module tube heat shield.





18. Connect the accelerator cable, the speed control actuator cable, the throttle return spring and the cable retaining bolts.





19. Connect the fuel charging wiring electrical connectors to the eight fuel injectors.





20. Connect the fuel charging wiring electrical connectors to the eight ignition coils.





21. Connect the coolant temperature sensor electrical connector.





22. Install the LH cowl extension.
1 Install the extension.
2 Install the bolts.
3 Connect the electrical connectors.





23. Install the RH cowl extension.
1 Install the extension.
2 Install the pin-type retainers.
3 Install the nuts and the bolts.
24. Install the wiper mounting arm and pivot shaft.
25. Connect the fuel spring lock coupling.
26. Install the air cleaner outlet pipe-resonator assembly.
27. Connect the battery ground cable.
28. Check the engine oil.

29. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of constant tension clamps.





Connect the upper radiator hose.
30. Fill and bleed the engine cooling system.