Intake Manifold: Service and Repair

1. Relieve fuel system pressure as outlined under "Precautions" and disconnect battery ground cable.
2. Disconnect fuel supply tube from rail, using a towel to catch any gasoline spillage.
3. Disconnect Manifold Absolute Pressure (MAP) and Intake Air Temperature (IAT) sensor electrical connectors.

Fig. 12 Exploded View Of Intake & Exhaust Manifolds.:

4. Remove plenum support bracket bolt, located rearward of MAP sensor.
5. Remove air inlet resonator to intake manifold bolt.
6. Loosen throttle body air inlet hose clamp, release snaps holding air cleaner housing cover to housing, then remove the air cleaner cover and inlet hoses.
7. Disconnect Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor electrical connectors.
8. Depress throttle cable retainer tab and pull cable rearward out of bracket, then repeat for speed control cable, if equipped.
9. Remove EGR tube from intake manifold.
10. Remove plenum support bracket bolt, rearward of EGR tube.
11. Remove upper intake plenum attaching bolts, then the plenum.
12. Disconnect fuel injector electrical connectors.
13. Remove four fuel rail attaching bolts and spacers, then the fuel rail.
14. Remove lower intake manifold attaching bolts, then the intake manifold.
15. Reverse procedure to install, noting the following:
a. Clean all mating surfaces, then inspect for cracked or distorted manifold and torn or missing O-rings.

Fig. 13 Intake Manifold Bolt Tightening Sequence.:

b. Install intake manifold with new gaskets and install intake manifold onto cylinder head tightening to specifications in sequence shown.
c. Tighten attaching nuts and bolts to specifications.