Intake Manifold: Service and Repair

Removal

WARNING:
^ Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.
^ Fuel in the fuel system remains under high pressure even when the engine is not running.

1. Disconnect the battery ground cable.
2. Relieve the fuel system pressure.
3. Drain the cooling system.





4. Compress and slide the hose clamp and disconnect the upper radiator hose.
5. Remove the engine Air Cleaner (ACL) and air cleaner outlet tube.





6. Remove the accelerator control splash shield.





7. Disconnect the throttle body cam.
^ Disconnect the accelerator cable.
^ If equipped, disconnect the speed control cable.
^ Remove the throttle return spring.





8. Position the accelerator cable bracket aside.
^ Remove the bolts.
^ Position the accelerator cable bracket aside.





9. Disconnect the throttle position sensor electrical connector.





10. Disconnect the engine vacuum hoses to the:
^ vapor management valve.
^ brake booster.
^ vacuum harness.





11. Disconnect the idle air control motor electrical connector.





12. If equipped, position the EGR transducer bracket aside.
^ Remove the bolts.
^ Position the bracket aside.





13. If equipped, position the EGR valve to exhaust manifold tube aside.
^ Disconnect the upper fitting.
^ Loosen the lower fitting.
^ Position the EGR valve to exhaust manifold tube aside.





14. If equipped, disconnect the engine vacuum regulator solenoid connections.





15. If equipped, disconnect the EGR vacuum line.





16. Remove the throttle body adapter.
^ Remove the four bolts.
^ Remove the throttle body adapter.
^ Remove and discard the throttle body gasket.
17. Disconnect the fuel lines.





18. Disconnect the RH fuel injector electrical connectors.





19. Disconnect the LH fuel injector electrical connectors.





20. Disconnect the two radio interference capacitors.
21. Remove the Generator (GEN).





22. Disconnect the water temperature indicator sender wiring and the cylinder head temperature sensor wiring.
23. Disconnect and remove the eight ignition coils.





24. Disconnect the PCV hose.





25. Disconnect the hose clamp and remove the heater water hose.
26. Remove the water thermostat.





27. Remove the bolts.





28. Remove the intake manifold.
^ Lift the intake manifold.
^ Remove and discard the intake manifold gaskets.

29. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths.

Clean all mating surfaces.

Installation





1. Install the intake manifold.
^ Position the intake manifold gaskets.
^ Position the intake manifold.
^ Loosely install the nine bolts.
2. Install the water thermostat.





3. Tighten the bolts in two stages, in the sequence shown.
1. Stage 1: Tighten to 2 Nm (18 inch lbs.).
2. Stage 2: Tighten to 20-30 Nm (15-22 ft. lbs.).





4. Install the heater water hose and position the clamp.





5. Connect the PCV valve tube.





6. Connect the water temperature indicator sender wiring and the cylinder head temperature sensor wiring connectors.
7. Install the generator.
8. Install the eight ignition coils.





9. Connect the LH fuel injector electrical connectors.





10. Connect the RH fuel injector electrical connectors.





11. Connect the two radio interference capacitors.
12. Connect the fuel lines.





13. Install the throttle body adapter.
^ Position the throttle body adapter gasket.
^ Position the throttle body adapter.
^ Install four bolts. Tighten the bolts in two stages.
^ Stage 1: Tighten to 8-10 Nm (71-88 inch lbs.).
^ Stage 2: Tighten an additional 85-95 degrees.





14. If equipped, connect the EGR valve to exhaust manifold tube upper fitting.
^ Tighten both fittings starting at the top in three steps.
^ Hand-tighten.
^ Tighten the upper fitting to 40-60 Nm (30-44 ft. lbs.).
^ Tighten the lower fitting to 40-60 Nm (30-44 ft. lbs.).





15. If equipped, connect the EGR valve vacuum line.





16. If equipped, connect the EVR solenoid connections.





17. If equipped, install the EGR transducer bracket.





18. Connect the idle air control motor electrical connector.





19. Connect the vacuum lines:
^ vapor management valve
^ brake booster
^ vacuum harness





20. Connect the throttle position sensor electrical connector.





21. Install the accelerator cable bracket.
^ Position the accelerator cable bracket.
^ Install the bolts.





22. Connect the throttle body cam.
^ Connect the accelerator cable.
^ If equipped, connect speed control cable.
^ Install the return spring.





23. Install the accelerator control splash shield.
24. Install the air cleaner outlet tube and the engine air cleaner.





25. Install the upper radiator hose and reposition the clamp.
26. Fill the cooling system.
27. Connect the battery ground cable.