Intake Manifold: Service and Repair

MANIFOLD-INTAKE

REMOVAL
1. Disconnect negative cable from battery.
2. Remove the wiper module.
3. Remove resonator assembly and air inlet hose.
4. Disconnect throttle and speed control cables.
5. Disconnect electrical connectors for the following components:
^ Manifold Absolute Pressure (MAP) Sensor
^ Intake Air Temperature (IAT) Sensor
^ Throttle Position (TPS) Sensor
^ Coolant Temperature (CTS) Sensor
^ Idle Air Control (IAC) Motor

6. Disconnect brake booster hose and positive crankcase ventilation (PCV) hose.
7. Disconnect generator electrical connections.
8. Disconnect air conditioning compressor electrical connections.
9. Disconnect left and right radio suppressor straps.
10. Disconnect and remove ignition coil towers.
11. Remove top oil dipstick tube retaining bolt and ground strap.
12. Bleed fuel system.
13. Remove fuel rail.
14. Remove throttle body assembly and mounting bracket.
15. Drain cooling system below coolant temperature level.
16. Remove the heater hoses from the engine front cover and the heater core.
17. Unclip and remove heater hoses and tubes from intake manifold.
18. Remove coolant temperature sensor.





19. Remove intake manifold retaining fasteners in reverse order of tightening sequence.
20. Remove intake manifold.

CLEANING

NOTE: There is NOT approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.

Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.

INSPECTION
1. Inspect the intake sealing surface for cracks, nicks and distortion.
2. Inspect the intake manifold vacuum hose fittings for looseness or blockage.
3. Inspect the manifold to throttle body mating surface for cracks, nicks and distortion.

INSTALLATION
1. Install intake manifold gaskets.
2. Position intake manifold.





3. Install intake manifold retaining bolts and tighten in sequence shown in to 12 Nm (105 inch lbs.).
4. Install left and right radio suppressor straps.
5. Install throttle body assembly.
6. Install throttle cable bracket.
7. Connect throttle cable and speed control cable to throttle body.
8. Install fuel rail.
9. Install ignition coil towers.
10. Position and install heater hoses and tubes onto intake manifold.
11. Install the heater hoses to the heater core and engine front cover.
12. Connect electrical connectors for the following components:
^ Manifold Absolute Pressure (MAP) Sensor
^ Intake Air Temperature (IAT) Sensor
^ Throttle Position (TPS) Sensor
^ Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor
^ Ignition coil towers
^ Fuel injectors

13. Install top oil dipstick tube retaining bolt and ground strap.
14. Connect generator electrical connections.
15. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose.
16. Fill cooling system.
17. Install the wiper module.
18. Install resonator assembly and air inlet hose.
19. Connect negative cable to battery.