Intake Manifold: Service and Repair

Fig. 10 Intake manifold replacement:

REPLACEMENT
1. Remove engine intake air resonators (9F763).
2. Depressurize fuel system. See Powertrain Management.
3. Disconnect battery ground cable (14301).
4. Remove accelerator cable (9A758) and speed control actuator cable (9A825) from throttle body (9E926) and accelerator cable bracket (9723).
5. Remove fuel injection supply manifold (9D280).
6. Disconnect fuel charging wiring (9D930) from engine coolant temperature sensor (ECT) (12A648) and engine control sensor wiring (12A581).
7. Remove crankcase ventilation tube (6758) from intake manifold fitting.
8. Remove camshaft position sensor (CMP) (6B288) from cylinder head (6049).
9. Remove EGR valve (9D475).
10. Remove vacuum supply hose for body from fitting at rear of intake manifold (9424) and vacuum supply hose for power brake booster (2005) from bottom of intake manifold.
11. Remove retaining bracket screws for the engine control sensor wiring from the intake manifold.
12. If necessary, remove the fuel charging wiring from the intake manifold.

NOTE: The intake manifold can be removed without the removal of the generator (GEN) (10300) and generator mounting bracket (10153), but with some difficulty.

13. If necessary, remove generator and generator mounting bracket.
14. Remove retaining bolts, nuts and studs for intake manifold. Remove the intake manifold and intake manifold gasket (9439) from cylinder head.
15. If necessary, remove the throttle body from the intake manifold.
16. If necessary remove idle air control valve (IAC) (9F715) from the intake manifold.
17. To install, reverse removal procedure. Tighten intake manifold retaining bolts and nuts to 16-20 Nm (12-15 ft. lbs.) in a standard-type torque sequence. Tighten screws for retaining bracket for engine control sensor wiring securely. Tighten retaining bolt for accelerator cable bracket to 8-12 Nm (71-106 inch lbs.).