Intake Manifold: Service and Repair

INTAKE MANIFOLD
REMOVAL

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.

1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect negative battery cable.
3. Drain cooling system.
4. Remove throttle body air inlet hose and air cleaner housing assembly.
5. Remove throttle and speed control cables from throttle lever and bracket.
6. Remove EGR tube.
7. Remove engine oil dipstick and tube from engine block. Plug hole in block to prevent debris or fluid from entering engine crankcase.
8. Disconnect necessary vacuum hoses from intake manifold.
9. Disconnect the fuel supply line quick connect at the fuel rail assembly.

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

10. Remove fastener holding fuel rail bracket to side of cylinder head.
11. Disconnect the following electrical connectors:
^ Fuel Injectors
^ Knock Sensor
^ ECT Sensor
^ JAC
^ TPS
^ MAP Sensor
^ A/C Pressure Sensor
^ A/C Compressor Clutch
^ Generator
12. Reposition wiring harness.





13. Remove fuel rail support bracket (Fig. 103).
14. Remove fuel rail.
15. Remove coolant outlet connector.
16. Remove intake manifold fasteners. Remove intake manifold.

CLEANING
1. Discard gasket(s).
2. Clean all sealing surfaces.

INSPECTION
1. Inspect manifold for cracks, distortion, or mounting surface warpage. Replace manifold if necessary.
2. Inspect manifold gasket for surface damage or excessive swelling. Replace gaskets as necessary.

INSTALLATION





1. Install new intake manifold and gasket. Gradually tighten fasteners to 28 Nm (250 inch lbs.) in sequence shown in (Fig. 104).
2. Install coolant outlet connector.
3. Install fuel rail.
4. Install fuel rail support bracket (Fig. 103).
5. Connect previously disconnected electrical connectors.
6. Install fastener holding fuel rail bracket to side of cylinder head.
7. Inspect quick connect fittings for damage, replace if necessary. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
8. Connect vacuum hoses to intake manifold.
9. Install engine oil dipstick and tube.
10. Install EGR tube.
11. Install throttle and speed control cables to bracket. Connect cables to the throttle lever.
12. Fill cooling system.
13. Connect negative battery cable.
14. 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.