Intake Manifold Replacement

REMOVAL

WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle.

1. Disconnect negative cable from battery.
2. Remove fuel filler cap.

Clean Air Duct To Throttle Body Assembly:

3. Remove the fresh air inlet duct from air cleaner.

Fuel Pressure Test Port:

4. Remove the protective cap from the fuel pressure test port on the fuel rail.

Releasing Fuel Pressure:

5. Place the open end of fuel pressure release hose, Special Tool C-4799-1, into an approved gasoline container. Connect the other end of hose to the fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-A contains hose C-4799-1.
6. Perform fuel system pressure release procedure before attempting any repairs.
7. Disconnect the fuel supply line quick connect at the fuel tube assembly.

WARNING: Wrap shop towels around hose to catch any gasoline spillage.

8. 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

9. Remove clean air duct and upper air filter
10. Remove accelerator, kickdown and speed control cables from throttle lever and bracket.

Idle Air Control (IAC) Motor And Throttle Position Sensor (TPS) Wiring Connectors And Vacuum Hose Connection:

11. Disconnect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.
12. Disconnect vacuum hisses from throttle body.

Intake Manifold Electrical And Vacuum Hose Connections:

13. Disconnect Manifold Absolute Pressure/Intake Air Temperature Sensor (TMAP), electrical connector. Disconnect vapor and brake booster hoses.

Knock Sensor:

14. Disconnect knock sensor electrical connector and disconnect wiring harness from tab located on the intake manifold.
15. Disconnect wiring at starter.
16. Remove transmission to throttle body support bracket fasteners at the throttle body and loosen the fasteners at the transmission end.
17. Remove throttle body.

EGR Tube Assembly:

18. Remove EGR tube bolts at the valve and at the intake manifold. Remove tube from engine.

Intake Manifold Tightening Sequence:

19. Remove the intake manifold to inlet water tube support fastener.
20. Remove 10 intake manifold screws and washers. Discard the fasteners. Remove intake manifold.

INSTALLATION
Before installing manifold. Clean all mating surfaces. Replace all seals, with new seals. All intake manifold fasteners and washers are to be discarded and NEW fasteners and washers are to be used.
1. Install intake manifold onto cylinder head and tighten fasteners to 12 Nm (105 inch lbs.) in sequence shown.
2. Install intake manifold to water inlet support. Tighten fastener to 12 Nm (105 inch lbs.).
3. 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.).
4. Connect PCV and brake booster hoses.
5. Inspect quick connect fittings for damage, replace if necessary. Apply a light amount of clean engine oil to fuel inlet tube. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
6. 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.
7. Connect Manifold Absolute Pressure/Intake Air Temperature Sensor (TMAP) wiring connector.
8. Connect knock sensor connector, and wiring at starter. Connect wiring harness to intake manifold tab.
9. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.
10. Connect vacuum hoses to throttle body.
11. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever.
12. Loose 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.).
13. Install clean air duct to air filter housing. Tighten clamp to 3 Nm (30 inch lbs.).
14. Connect negative cable to battery.
15. Install fresh air duct to air cleaner and tighten wing nut.
16. 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.