Intake Manifold: Service and Repair

1. Disconnect battery ground cable, then drain cooling system.
2. Relieve fuel system pressure.
3. Remove air cleaner outlet tube, then release drive belt tensioner and remove drive belt.
4. Disconnect all ignition wires from spark plugs.
5. Disconnect ignition wire and brackets from camshaft cover studs.
6. Disconnect both ignition coils and camshaft position sensor.
7. Remove four bolts retaining ignition coil to ignition coil brackets.
8. Disconnect alternator wiring harness from junction block at front fender apron and from alternator.
9. Remove two bolts retaining alternator mounting bracket to intake manifold.
10. Remove two bolts retaining alternator to cylinder block, then remove alternator.
11. Raise and support vehicle.
12. Disconnect oil pressure sender and EVO harness sensor and reposition wiring for clearance.
13. Disconnect EGR valve to exhaust manifold tube from right exhaust manifold.
14. Lower vehicle, then disconnect accelerator cable and speed control actuator from throttle body.
15. Remove accelerator cable bracket from intake manifold and position clear of area.
16. Disconnect throttle valve control actuating cable from throttle body.
17. Disconnect vacuum hose from throttle body adapter vacuum port.
18. Disconnect heater supply hose.
19. Remove two bolts retaining thermostat housing to intake manifold and position upper radiator hose and thermostat housing clear of manifold.
20. Remove nine bolts retaining intake manifold to cylinder heads, then remove intake manifold and gaskets.
21. Reverse procedure to install, noting the following:
a. Ensure alignment tabs on intake manifold gasket are aligned with holes in cylinder head.

Intake Manifold:

b. Torque nine intake manifold retaining bolts in sequence to 15-22 ft lb.
c. Replace O-ring on thermostat housing.
d. Fill and bleed cooling system