Intake Manifold Replacement

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

To release fuel pressure, refer to Powertrain Management for procedure.

REMOVAL
1. Perform fuel system pressure release procedure before attempting any repairs.

Figure 23:

2. Disconnect negative cable from auxiliary jumper terminal (Fig. 23).
3. Remove Air Inlet Resonator.
4. Disconnect the fuel supply line quick connect at the fuel rail assembly.

WARNING: WRAP SHOP TOWELS AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.

5. Remove fuel rail assembly attaching screws and remove fuel rail assembly from engine. Cover injector holes with suitable covering.

CAUTION: Do not set fuel injectors on their tips, damage may occur to the injectors

6. Remove accelerator, kickdown and speed control cables from throttle lever and bracket.

Figure 25:

7. Disconnect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors (Fig. 24).

Figure 24:

8. Disconnect intake air temperature sensor, leak detection pump and PCV hoses (Fig. 24).

Figure 26:

9. Disconnect intake air temperature electrical connector. Disconnect leak detection pump and PCV hoses (Fig. 26).
10. Remove transmission to throttle body support bracket fasteners at the throttle body and loosen the fastener at the transmission end.

Figure 27:

11. Remove EGR tube bolts at the valve and at the intake manifold (Fig. 27). Remove tube from engine.
12. Remove the intake manifold support bracket.
13. Remove intake manifold fasteners and washer assemblies. Remove intake manifold.


INSTALLATION

Figure 28:

1. Install new intake manifold gasket, and manifold onto cylinder head and tighten fasteners to 11.9 Nm (105 inch lbs.) in sequence shown (Fig. 28).
2. Remove covering from fuel injector [holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 inch lbs.).
3. Connect PCV and brake booster hoses.
4. Inspect quick connect fittings for damage, replace if necessary Lube tube with clean 30w engine oil, Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
5. Install throttle body. Tighten fastener to 22 Nm (200 inch lbs.). Install transmission to throttle body support bracket and tighten to 11.9 Nm (105 inch lbs.) at the throttle body first. Next tighten the bracket at the transmission.
6. Connect Manifold Absolute Pressure (MAP) and intake air temperature sensor wiring connectors.
7. Connect knock sensor electrical and starter relay connectors. Connect wiring harness to intake manifold tab.
8. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.
9. Connect vacuum hoses to throttle body.
10. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever. Refer to Throttle Body, Installation procedure.
11. Loosely assemble the EGR tube onto valve and intake manifold finger tight. Tighten tube fasteners at the EGR valve first to 11 Nm (95 inch lbs.) then, tighten the intake manifold side fasteners to 11 Nm (95 inch lbs.).
12. Connect negative cable from auxiliary jumper.
13. With the DRB scan tool use ASD Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.