Intake Manifold: Service and Repair

REMOVAL

1. Partially drain the cooling system. Refer to Cooling System.
2. Remove the air cleaner outlet tube. Refer to Powertrain Management.





3. Remove the vacuum hoses at the (A) exhaust gas recirculation (EGR) valve, the (B) positive crankcase ventilation (PCV) valve, the (C) throttle body, the (D) fuel pressure regulator, and the (E) intake manifold.





4. Disconnect the (A) speed control cable (if equipped), the (B) accelerator cable (9A758), and the (C) throttle valve control actuating cable (7F042) (AT only) from the throttle control lever (9A776).





5. Remove the two speed control cable bracket bolts and position the bracket and cables aside.





6. Disconnect the (A) idle air control (IAC) valve and the (B) throttle position (TP) sensor electrical connectors.
7. Remove the oil level indicator tube bracket bolt from the intake manifold.





8. Disconnect the EGR manifold tube located just below the EGR valve.
9. Raise and support the vehicle.





10. Remove the oil level indicator tube from the engine block.
11. Remove the four lower intake manifold nuts.
12. Lower the vehicle.
13. Remove the four upper intake manifold nuts and remove the intake manifold (9424) and gasket.

INSTALLATION

CAUTION: Do not use abrasive grinding discs to remove the gasket material; use only manual scrapers. Do not scratch or gouge aluminum sealing surfaces.

1. Clean and inspect the mounting faces of both the intake manifold and the cylinder head. Both surfaces must be clean and flat.
2. Clean and oil the manifold studs.
3. Install the gasket and the intake manifold. Hand tighten the four upper intake manifold nuts.
4. Raise and support the vehicle.
5. Install the four lower manifold nuts and tighten to 20-30 Nm (15-22 ft. lbs.).
6. Install the oil level indicator tube.
7. Lower the vehicle.
8. Tighten the upper intake manifold nuts to 20-30 Nm (15-22 ft. lbs.).
9. Install the EGR manifold tube.
10. Install the oil level indicator tube bolt and tighten to 8-11.5 Nm (70-101 inch lbs.).
11. Connect the IAC valve electrical and the TP sensor connectors.
12. Install the speed control cable bracket and bolts and tighten to 7.8-10.8 Nm (64-87 inch lbs.).
13. Connect the speed control cable, the accelerator cable, and the throttle valve control actuating cable to the throttle control lever.
14. Install the vacuum hoses at the exhaust gas recirculation (EGR) valve, the positive crankcase ventilation (PCV) valve, the throttle body, the fuel pressure regulator, and the intake manifold.
15. Install the air cleaner outlet tube. Refer to Powertrain Management.
16. Refill the cooling system.
17. Start the engine (6007) and check for coolant leaks.