Intake Manifold: Service and Repair

Intake Manifold

Intake Manifold:

Removal

1. WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to Fire Suppression System.

With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the fuel tube spring lock coupling.
3. Disconnect the battery ground cable.
4. Drain the engine cooling system.
5. Remove the air cleaner and outlet pipe.
6. Remove the wiper mounting arm and pivot shaft.
7. Disconnect the 8 fuel injector electrical connectors.
8. Remove the 8 ignition coil-on-plugs.
9. Remove the 2 intake manifold shield bolts and the shield.
10. Disconnect the brake booster vacuum hose from the intake manifold.
11. Disconnect the quick connect coupling evaporative emission (EVAP) canister purge valve hoses from the throttle body (TB) spacer and from the EVAP canister purge valve.
12. Disconnect the quick connect coupling positive crankcase ventilation (PCV) tube from the TB spacer.
13. Disconnect the exhaust gas recirculation (EGR) system module vacuum and electrical connectors.
14. Disconnect the intake manifold-to-TB spacer vacuum hose.
15. Disconnect the generator electrical connector.
16. Remove the 4 generator bracket bolts and the bracket.
17. Remove the coolant thermostat.
18. Disconnect the throttle control and the throttle position (TP) sensor electrical connector.
19. Release the heater hose spring clamp and disconnect the heater hose.
20. Remove the EGR system module tube.
21. If equipped, detach the wire harness retainer from the intake manifold crash bracket.
22. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.





23. Remove the intake manifold crash bracket bolt.
24. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
25. Remove the wire harness retainer from the LH front fuel rail stud.
26. Remove the wire harness retainer from the rear of the intake manifold.
27. Disconnect the ground connector from the RH rear fuel rail stud bolt.
28. Remove the 8 bolts and the intake manifold.
29. Remove and discard the intake manifold gaskets.
30. Clean the sealing surfaces.

Installation

1. NOTE: Align the gasket locator tabs with the slots in the cylinder head.

Install new intake manifold gaskets.





2. Install the intake manifold and hand-tighten the 8 bolts.
3. Install the 8 ignition coil-on-plugs.
4. Position the intake manifold crash bracket and loosely install the bolt and stud bolt.
5. Tighten the bolts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).





6. Tighten the intake manifold crash bracket bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
7. Install the exhaust gas recirculation (EGR) system module tube.
8. Install the intake manifold shield and the 2 bolts.
^ Tighten to 12 Nm (9 ft. lbs.).
9. Connect the throttle control and the TP sensor electrical connectors.
10. Install the coolant thermostat.
11. Install the generator bracket and the 4 bracket bolts.
^ Tighten to 10 Nm (89 inch lbs.).
12. Connect the generator electrical connector.
13. Connect the evaporative emission (EVAP) canister purge valve hoses to the TB and the EVAP canister purge valve.
14. Connect the intake manifold vacuum hose to the TB spacer.
15. Connect the EGR system module vacuum and electrical connectors.
16. Connect the PCV tube quick connect coupling to the TB spacer.
17. Connect the brake booster vacuum hose to the intake manifold.
18. Install the heater hose and spring clamp.
19. Connect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
20. Connect the 8 fuel injector electrical connectors.
21. Install the wire harness retainer to the rear of the intake manifold.
22. Attach the wire harness retainer to the LH front fuel rail stud.
23. If equipped, attach the wire harness retainer to the intake manifold crash bracket.
24. Connect the ground connector to the RH rear fuel rail stud bolt.
25. Install the wiper mounting arm and pivot shaft.
26. Connect the fuel spring lock coupling.
27. Install the air cleaner and outlet pipe.
28. Connect the battery ground cable.
29. Fill and bleed the engine cooling system.

30. WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System.

If equipped with fire suppression system, repower the system.