Intake Manifold: Service and Repair

Fig. 4 Intake Manifold Installation:

1. Disconnect battery ground cable.
2. Disconnect accelerator and T.V. cable bracket at plenum.
3. Disconnect brake vacuum pipe and plug harness at plenum.
4. Disconnect throttle body at plenum.
5. Disconnect EGR pipe at EGR valve, then remove plenum.
6. Disconnect fuel inlet and return pipes at fuel rail.
7. Remove serpentine belt, then disconnect alternator assembly and position aside.
8. Remove power steering lines at alternator bracket, then remove power steering pump attaching bolts and position aside.
9. Loosen alternator bracket attaching bolts.
10. Remove idle air to throttle body vacuum hose, then disconnect fuel injector electrical connectors.
11. Remove fuel rail and breather tube.
12. Remove plug wires at intake manifold.
13. Remove rocker arm covers and drain cooling system.
14. Remove radiator hose at thermostat outlet.
15. Disconnect coolant sensor and oil sending switch electrical connectors, then remove coolant sensor.
16. Remove filler neck to cylinder head bypass hose, then remove heater inlet pipe at manifold.
17. Remove intake manifold attaching bolts, then remove intake manifold.
18. Reverse procedure to install. Refer to Fig. 4, for intake manifold tightening sequence and specifications.