Intake Manifold: Service and Repair

Removal





1. Remove the intake manifold cover.





2. Remove the evaporative emission (EVAP) canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C).





3. Disconnect the intake air temperature (IAT) sensor connector (A), and remove the breather hose (B), then remove the air cleaner housing cover/intake air duct assembly (C).





4. Fully open the throttle link and cruise control link by hand, then remove the throttle cable (A) and cruise control cable (B) from the links. Loosen the locknuts (C), and remove the cables from the bracket.





5. Be prepared to catch and clean up spilled coolant. Remove the water bypass hoses, then plug the water bypass hoses.
6. Relieve fuel pressure.
7. Remove the fuel line.





8. Remove the positive crankcase ventilation (PCV) hose (A), harness holder mounting bolt (B) and harness clamp mounting bolt (C).
9. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
^ Four injector connectors
^ Idle air control (IAC) valve connector
^ Throttle position (TP) sensor connector
^ Manifold absolute pressure (MAP) sensor connector
^ Evaporative emission (EVAP) canister purge valve connector





10. Remove the bolt securing the intake manifold and bracket.





11. Remove all the intake manifold mounting bolts/nuts.
12. Remove the two stud bolts (A), then remove the intake manifold (B).

Installation





1. Install the intake manifold (A) with a new gasket (B), then install and tighten the two stud bolts (C).
2. Tighten all intake manifold mounting bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt.





3. Tighten the bolt securing the intake manifold and bracket.





4. Install the PCV hose (A), harness holder mounting bolt (B), and harness clamp mounting bolt (C).
5. Install the fuel line.





6. Install the water bypass hoses.
7. Install the throttle cable, then adjust the cable.
8. Install the cruise control cable, then adjust the cable.





9. Install the air cleaner housing cover (A), and connect the IAT sensor connector (B).
10. Install the breather hose (C).





11. Install the EVAP canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C).





12. Install the intake manifold cover.
13. Clean up any spilled engine coolant.
14. After installation, check that all tubes, hoses, and connectors are installed correctly.
15. Inspect for fuel leaks.Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
16. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.