Intake Manifold: Service and Repair

1. Relieve fuel system pressure as outlined under "Precautions" and disconnect battery ground cable.
2. Remove air inlet resonator.
3. Disconnect fuel supply line quick connect from fuel tube assembly.
4. Remove fuel rail assembly attaching screws, then the fuel rail assembly cover injector holes.
5. Remove accelerator, kickdown and speed control cables from throttle lever and bracket.
6. Disconnect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) electrical connectors.
7. Disconnect vacuum hoses from throttle body.
8. Disconnect Manifold Absolute Pressure (MAP) intake air temperature electrical connectors.
9. Disconnect vapor and brake booster hoses.
10. Disconnect knock sensor electrical connector and harness from tab located on intake manifold .
11. Remove transaxle to throttle body support bracket bolts at throttle body and loosen bolt at transaxle.
12. Remove EGR tube attaching bolts, then the tube.
13. Remove intake manifold to inlet water tube support bolt and manifold support bracket, if required.
14. Remove ten intake manifold attaching bolts and washers, then the intake manifold.
15. Reverse procedure to install, noting the following:
a. Clean all mating surfaces, then check for cracked or distorted manifold and torn or missing O-rings.

Fig. 9 Intake Manifold Bolt Tightening Sequence.:

Fig. 6 Intake Manifold Bolt Tightening Sequence.:

Fig. 11 Intake Manifold Bolt Tightening Sequence:

b. Tighten intake manifold attaching bolts in sequence to specifications.
c. Tighten attaching nuts and bolts to specifications.