Intake Manifold: Service and Repair

NOTE: On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.

1. Release fuel system pressure as outlined in Technician Safety Information.
2. Disconnect battery ground cable.

Fig. 2 Air Cleaner Housing Replacement:

3. Remove air cleaner housing and air intake tube from throttle body, Fig. 2.
4. Disconnect mass air flow sensor (MAF) electrical connector.
5. On models with automatic transaxle, disconnect accelerator cable and automatic transaxle control cable.
6. Disconnect the following electrical connectors:
a. Throttle position sensor.
b. Bypass idle air control valve and EGR control valve.
c. Main injector harness.
d. Distributor connectors.
e. Engine coolant temperature sensor and sender.
7. Disconnect brake vacuum hose, purge control vacuum hose.
8. Disconnect fuel lines from fuel injector rail, noting the following:
a. Cover hose with rag to prevent fuel spraying out when disconnecting.
b. Plug disconnected hoses to avoid fuel leakage.
9. Disconnect purge solenoid and cruise control vacuum hoses.

Fig. 7 Intake Manifold Replacement:

10. Remove nine intake manifold mounting nuts from cylinder head, then remove intake manifold assembly, Fig. 7.
11. Reverse procedure to install, noting the following:
a. Tighten all bolts and nuts to specifications.
b. Refill radiator with coolant and bleed cooling system.