Intake Manifold: Service and Repair

REMOVAL
1. Relieve fuel pressure according to procedure described. Refer to Powertrain Management; Fuel Delivery and Air Induction.
2. Disconnect negative cable at battery.





3. Drain cooling system.

WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.





4. Disconnect accelerator cable from throttle body.





5. Disconnect following electric lead wires and release clamps.
^ EGR valve.
^ EVAP canister purge valve.
^ Ground wires from intake manifold and throttle body.
^ Fuel injectors.
^ TP sensor.
^ IAC valve.
^ Tank pressure control solenoid vacuum valve
^ MAP sensor.





6. Disconnect following hoses:
^ Brake booster hose from intake manifold.
^ EVAP canister purge hose from EVAP canister.
^ Engine cooling water (coolant) hoses from IAC valve and intake manifold.
^ Tank pressure control solenoid vacuum hose from tank pressure control valve.
^ PCV hose.





7. Disconnect fuel feed hose from pipe, and disconnect fuel return hose from fuel pressure regulator.





8. Remove intake manifold rear stiffener bolt, generator adjust arm reinforcement bolt and right mounting bracket stiffener bolt from intake manifold.





9. Remove intake manifold with throttle body from cylinder head, and then its gasket.

INSTALLATION
Reverse removal procedure for installation noting the followings.
^ Use new intake manifold gasket.





^ When installing intake manifold, install clamps at positions as shown in figure.





^ Adjust accelerator cable play.
^ Check to ensure that all removed parts are back in place.
^ Reinstall any necessary parts which have not been reinstalled.
^ Refill cooling system.
^ Upon completion of installation, turn ignition switch ON but engine OFF and check for fuel leaks.
^ Finally, start engine and check for engine coolant leaks.