Intake Manifold: Service and Repair
Removal Procedure1. Relieve the fuel pressure. Refer to Relieving Fuel Pressure in Powertrain Management.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
2. Disconnect the negative battery cable.
3. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the air cleaner assembly.
5. Disconnect the following electrical connectors:
^ The engine coolant temperature (ECT) sensor connector
^ The coolant temperature sending unit connector
^ The throttle position (TP) sensor electrical connector
^ The exhaust gas recirculation solenoid vacuum valve
^ The Idle Speed Control (ISC) motor electrical connector
^ The ground wire bolts and ground wires from the intake manifold
^ The throttle body fuel injection (TBI) unit electrical connector
^ The early fuel evaporation (EFE) heater electrical connector (if equipped)
^ The release wiring harness from the retaining clamps
6. Remove the fuel return hose (2) and the fuel feed hose (3) from the TBI unit (4).
7. Remove the coolant hoses (2) (3) and (4) from the TBI unit and the intake manifold.
8. Remove the EGR modulator.
9. Remove the EGR valve.
10. Remove the following vacuum hoses:
^ The evaporative emissions (EVAP) canister hose from the EVAP canister pipe
^ The manifold absolute pressure sensor hose from the Throttle Body (TB)
^ The brake booster hose from the intake manifold
11. Remove the positive crankcase ventilation (PCV) hose from the cylinder head cover.
12. Remove the accelerator cable from the TBI unit.
13. Remove the five nuts and two bolts from the intake manifold.
14. Remove the intake manifold (4) with the TBI unit (1) and wire clamps from the cylinder head still attached.
15. Remove the intake manifold gasket (5) from the cylinder head.
Installation Procedure
1. Install the new intake manifold gasket (5) to the cylinder head.
2. Install the intake manifold with the TBI unit (1) and wire clamps to the cylinder head still attached.
NOTICE: Refer to Fastener Notice in Service Precautions.
3. Secure the intake manifold with the five nuts and two bolts.
Tighten the intake manifold fasteners to 23 Nm (17 ft. lbs.).
4. Install the PCV hose to the cylinder head cover.
5. Install the following vacuum hoses:
^ The EVAP canister hose
^ The manifold absolute pressure sensor hose to the intake manifold or to the TB
^ The brake booster hose to the intake manifold
6. Install the coolant hoses (2, 3, and 4) to the TBI unit (4) and the intake manifold.
7. Install the fuel return (2) and the fuel feed (3) hoses to the TBI unit (4).
8. Connect the following electrical connectors:
^ The ECT sensor electrical connector
^ The coolant temperature sending unit connector
^ The EFE heater electrical connector (if equipped)
^ The ECT switch electrical connector
^ The TP sensor electrical connector
^ The EGR solenoid vacuum valve electrical connector
^ The ISC motor electrical connector
^ The ground wires to the intake manifold
^ The TBI unit electrical connector
9. Secure the wiring harness to the retaining clamps.
10. Install the accelerator cable to the TBI unit.
11. Adjust the accelerator cable play to specifications. Refer to Accelerator Cable Replacement in Powertrain Management.
12. Install the air cleaner assembly to the TBI unit.
13. Reconnect the negative battery cable.
14. Refill the engine coolant.
15. Upon completion of the installation, start the engine and check for fuel and engine coolant leaks.