Intake Manifold: Service and Repair

Removal Procedure





1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery cable.
4. Disconnect the evaporative emission canister purge solenoid from the intake manifold and loosen the bracket bolt.
5. Drain the engine coolant. Refer to Coolant; Service and Repair.
6. Disconnect the intake air temperature sensor connector.





7. Disconnect the air intake tube from the throttle body
8. Disconnect the idle air control valve connector.





9. Disconnect the throttle position sensor connector.
10. Disconnect the manifold absolute pressure (MAP) sensor connector.
11. Disconnect the coolant hoses at the throttle body.
12. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.





13. Disconnect the throttle cable from the throttle body and the intake manifold.
14. Remove the throttle cable bracket bolts from the intake manifold.
15. Remove the throttle cable bracket.
16. Remove the generator-to-intake manifold strap bracket bolts and strap.
17. Remove the fuel rail and injector cover as an assembly. Refer to Powertrain Management.





18. Remove the generator-to-intake manifold support bracket bolts.
19. Remove the generator-to-intake manifold support bracket.
20. Remove the intake manifold support bracket bolt at the engine block and the intake manifold.
21. Remove the intake manifold support bracket.





22. Remove the intake manifold retaining bolt and nuts in the sequence shown.
23. Remove the intake manifold.
24. Remove the intake manifold gasket.
25. Clean the sealing surfaces of the intake manifold and the cylinder head.

Installation Procedure
1. Install the intake manifold gasket.
2. Install the intake manifold.





3. Install the intake manifold retaining bolt and nuts in the sequence shown.
Tighten the intake manifold retaining bolt and nuts to 22 Nm (16 ft. lbs.).
4. Install the generator-to-intake manifold strap bracket and bolts.
Tighten the generator-to-intake manifold strap bracket bolts to 20 Nm (15 ft. lbs.).
5. Install the intake manifold support bracket.
6. Install the intake manifold support bracket upper bolts to the intake manifold.
Tighten the intake manifold support bracket upper bolts to the intake manifold to 20 Nm (15 ft. lbs.).
7. Install the intake manifold support bracket lower bolt to the engine block.
Tighten the intake manifold support bracket lower bolt to the engine block to 20 Nm (15 ft. lbs.).





8. Install the generator-to-intake manifold support bracket and bolts.
Tighten the generator-to-intake manifold support bracket bolts to 35 Nm (26 ft. lbs.).
9. Install the fuel rail and injector cover as an assembly. Refer to Powertrain Management.





10. Install the throttle cable bracket.
11. Install the throttle cable bracket bolts.
Tighten the throttle cable bracket bolts to 8 Nm (71 inch lbs.).
12. Connect the throttle cable to the intake manifold and the throttle body.
13. Connect all of the necessary vacuum lines that were previously disconnected.
14. Connect the MAP sensor connector.
15. Connect the coolant hoses to the throttle body.
16. Connect the idle air control valve connector.





17. Connect the throttle position sensor connector.





18. Connect the air intake tube to the throttle body.
19. Connect the intake air temperature sensor connector.
20. Connect the evaporative emission canister purge solenoid at the intake manifold and tighten the bracket bolt.
Tighten the evaporative emission canister purge solenoid bracket bolt to 5 Nm (44 inch lbs.).
21. Install the fuel pump fuse.
22. Connect the negative battery cable.
23. Refill the engine cooling system. Refer to Coolant; Service and Repair.