Intake Manifold: Service and Repair

Fig. 2 Fuel Rail & Throttle Body Replacement:

Fig. 3 Intake Manifold Replacement:

Fig. 4 Intake Manifold Bolt Tightening Sequence:

1. Disconnect battery ground cable, then drain cooling system.
2. Remove throttle body air duct, then disconnect electrical connectors from fuel injectors.
3. Disconnect left and right hand wiring harness and position aside.
4. Remove accelerator cable bracket and disconnect cable from throttle body.
5. Disconnect hoses from AIR diverter valve.
6. Disconnect ground strap from intake manifold.
7. Remove retaining bolts from fuel rail.
8. Disconnect vacuum hose from fuel pressure regulator.
9. Relieve fuel system pressure as described under MAINTENANCE PROCEDURE/RELIEVING FUEL SYSTEM PRESSURE then disconnect and cap fuel lines at fuel rail.
10. Remove fuel injectors and fuel rail from intake manifold and position aside, Fig. 2.
11. Disconnect vacuum and PCV hoses from intake manifold.
12. Remove EGR solenoid bracket and fuel vapor canister purge solenoid bracket.
13. Remove EGR valve.
14. Disconnect air pipe from intake manifold and right hand exhaust manifold.
15. Remove alternator brace.
16. Disconnect coolant hoses from throttle body.
17. Remove throttle body to intake manifold mounting bolts, then remove throttle body and gasket, Fig. 2.
18. Remove intake manifold to engine block attaching bolts and studs, then remove intake manifold and gasket, Fig. 3.
19. Reverse procedure to install. Prior to installation, apply a 3/16 inch bead of sealer 1052366 or equivalent to front and rear of engine block. Extend bead of sealer 1/2 inch up each cylinder head to seal and retain gaskets. Install manifold and torque bolts to specifications in sequence shown in Fig. 4.