Intake Manifold: Service and Repair

1. Relieve fuel system pressure as outlined under Fuel System Pressure Relief.
2. Disconnect battery ground cable.
3. Remove air cleaner inlet hose from throttle body.
4. Remove throttle cable and speed control cable, if equipped, from throttle lever.
5. Remove throttle cable from bracket by compressing tabs.
6. Disconnect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) electrical connectors.
7. Disconnect and tag for installation reference vacuum hoses from intake plenum.
8. Disconnect Manifold Absolute Pressure (MAP) sensor electrical connector.
9. Remove fuel hose fitting from chassis tube. Place shop towel around hoses to prevent gas spillage.
10. Remove EGR tube and gasket at EGR valve.
11. Drain cooling system, then remove accessory drive belt.
12. Remove alternator bracket, if necessary.
13. Remove intake support bracket bottom bolts.
14. Remove intake manifold bolts, then manifold.
15. Remove fuel rail bolts, then fuel rail. Do not damage injector O-rings when removing from ports.
16. Reverse procedure to install, noting the following:
a. Clean all mating surfaces, then check for cracked or distorted manifold and torn or missing O-rings.

Fig. 6 Intake Manifold Bolt Tightening Sequence.:

b. Tighten intake manifold attaching bolts to specifications in sequence shown, Fig. 6.