Intake Manifold: Service and Repair

1. Remove engine air intake resonators.
2. Depressurize fuel system.
3. Disconnect battery ground cable, then remove accelerator cable and speed control actuator from throttle body and accelerator cable bracket.
4. Remove fuel injection supply manifold.
5. Disconnect fuel charging wiring from engine coolant temperature sensor and engine control sensor wiring, then remove the crankcase ventilation tube from intake manifold fitting as follows:.
a. Raise and support vehicle, then drain the cooling system.
b. Disconnect crankcase ventilation tube from positive crankcase ventilation valve.
c. Disconnect upper radiator hose and radiator overflow hose from water hose connection.
d. Remove water outlet connection bolts and water hose connection from water thermostat housing.
e. Remove water thermostat and seals from water thermostat and water thermostat housing, then inspect seals for damage and replace if necessary.
f. Remove crankcase ventilation tube bolt from rear of engine, then lower vehicle.
g. Disconnect front vapor hose from crankcase ventilation tube at connector on crankcase ventilation tube.
h. Disconnect crankcase ventilation tube from fitting on intake manifold, then remove tube.
6. Remove camshaft position sensor from cylinder head by disconnecting fuel charging wiring from sensor, then removing sensor screw and sensor.
7. Remove EGR valve, then vacuum supply hose for body from fitting at rear of intake manifold and vacuum supply hose for power brake booster from bottom of intake manifold.
8. Remove bracket screws for electrical control sensor wiring from intake manifold
9. If necessary, remove fuel charging wiring from intake manifold.
10. Remove alternator and bracket, if necessary. Intake manifold can be removed without first removing alternator and bracket, but with some difficulty.

Fig. 10 Intake manifold replacement:

11. Remove intake manifold bolts, nuts and studs, then intake manifold and gasket from cylinder head.
12. Remove throttle body and idle air control valve from intake manifold as necessary.
13. Reverse the procedure to install.