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. Remove fuel rail trim cover by pulling straight off fuel rail studs (Fig. 122).





4. Disconnect charge air cooler to throttle body hose (Fig. 123).
5. Disconnect vacuum hoses from throttle body and intake manifold.
6. Disconnect throttle cable from throttle body.
7. Disconnect Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor electrical connectors





8. Remove intake manifold support bracket (Fig. 124).





9. Disconnect fuel injector electrical connectors (Fig. 125). Unclip injector wiring harness from fuel rail.
10. Disconnect MAP sensor electrical connector (Fig. 125).
11. Disconnect the fuel supply line quick connect at the fuel rail assembly (Fig. 125).

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

12. Remove intake manifold fasteners.
13. Remove intake manifold.

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

INSPECTION
1. Inspect manifold for cracks or distortion. Replace manifold if necessary.
2. Inspect manifold for gasket surface damage or warpage. Replace manifold if necessary.

INSTALLATION
1. Clean all gasket surfaces.
2. Replace intake manifold gasket.
3. Install intake manifold. Tighten fasteners to 23 Nm (200 inch lbs.).
4. If removed, install the fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 inch lbs.).
5. Inspect fuel supply line quick connect fitting for damage, replace if necessary (Refer to - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE). Lubricate tube with clean engine oil. Connect fuel supply line to fuel rail assembly. Check connection by pulling on connector to insure it locked into position (Fig. 125).
6. Connect MAP sensor electrical connector (Fig. 125).
7. Connect fuel injector electrical connectors (Fig. 125). Clip injector wiring harness to fuel rail.
8. Install intake manifold support bracket. Tighten fasteners to 23 Nm (200 inch lbs.) (Fig. 124).
9. Connect Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor electrical connectors.
10. Connect throttle cable to throttle body.
11. Connect vacuum hoses to throttle body and intake manifold.
12. Connect charge air cooler to throttle body hose (Fig. 123).
13. Install fuel rail trim cover by pushing it over fuel rail studs (Fig. 122).
14. Connect negative cable to battery.
15. With the DRBIII scan tool use ASD Fuel System Test to pressurize the fuel 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.