Intake Manifold: Service and Repair

Intake Manifold

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. Drain the coolant system.
3. Remove the air cleaner outlet tube.





4. Compress and slide the hose clamp and disconnect the water outlet hose.





5. Remove the accelerator cable splash shield.
6. Relieve the fuel system pressure.





7. Disconnect the accelerator and speed control cables and remove the return spring.
8. On bi-fuel vehicles, remove the compuvalve and vaporizer.





9. Position the accelerator cable bracket aside.
^ Remove the bolts.
^ Position the bracket and cables aside.





10. Disconnect the PCV vacuum and coolant hoses.





11. Disconnect the vacuum lines:
^ brake booster
^ engine sensor control wiring harness





12. Remove the bolt (RH) and position the radio interference capacitor aside.





13. Disconnect the vacuum line.





14. Disconnect the five RH fuel injector electrical connectors and five ignition coil electrical connectors.





15. Disconnect the idle air control motor electrical connector and the bypass hose.





16. Disconnect the heater hose.





17. If equipped, disconnect the EGR transducer and disconnect the throttle position sensor connectors.





18. If equipped, disconnect the EGR transducer vacuum lines.





19. If equipped, remove the EGR transducer bracket.





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





21. If equipped, disconnect the EGR valve vacuum line.

22. NOTE: The EGR valve is shown removed for clarity.





If equipped, disconnect the EGR solenoid electrical and vacuum harness.

23. NOTE: The idle air control valve is shown removed for clarity.





Remove the throttle body adapter.
^ Remove the four bolts.
^ Remove the throttle body adapter.
^ Remove the throttle body adapter gasket.





24. If equipped, remove the EGR bracket.
^ Remove the bolts.
^ Remove the bracket.





25. Disconnect the five LH fuel injector electrical connectors and ignition coil connectors.





26. Disconnect the water temperature indicator sender unit electrical connectors.
27. Remove the Generator (GEN).





28. Remove the ignition coils.
^ Remove the 10 bolts.
^ Remove the 10 ignition coils.
29. Disconnect the fuel injection supply manifold.
^ Disconnect the fuel lines.
^ Disconnect the vacuum connector from the fuel pressure regulator.





30. Remove the bolt and position the capacitor aside.





31. Disconnect the cylinder head temperature sensor.
32. Remove the water thermostat and housing.





33. Remove the bolts, the upper intake manifold and the intake manifold gaskets. Discard the intake manifold gaskets.





34. If necessary, remove the fuel injection supply manifold.
^ Remove the four bolts.
^ Remove the fuel injection supply manifold.





35. Separate the upper and lower intake manifolds.
^ Remove the 10 bolts.

36. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths.

Clean all mating surfaces.

Installation





1. Position the lower intake manifold to the upper intake manifold and loosely install the 10 bolts.

2. NOTE: Tighten the bolts in two stages.





Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).





3. If necessary, install the fuel injector supply manifold.
^ Position the fuel injection supply manifold.
^ Install the seven bolts.
4. Position the water thermostat and housing.





5. Install the upper intake manifold.
^ Position the upper intake manifold gaskets and the intake manifold, and loosely install the bolts.





6. Tighten the bolts in two stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).





7. Connect the cylinder head temperature sensor.





8. Install the LH radio interference capacitor.
9. Connect the fuel lines and the vacuum line to the fuel injection supply manifold.





10. Install the ignition coils.
^ Position the 10 ignition coils.
^ Install the 10 bolts.
11. Install the generator.





12. Connect the water temperature indicator sending unit electrical connector.





13. Connect the five LH fuel injector electrical connectors and five LH ignition coil connectors.





14. If equipped, install the EGR solenoid bracket.
^ Position the bracket.
^ Install the bolts.

15. NOTE: The idle air control valve is shown removed for clarity.





Install the throttle body adapter.
^ Position a new throttle body adapter gasket.
^ Position the throttle body adapter.
^ Install four bolts and tighten in two stages.
^ Stage 1: Tighten to 9 Nm (80 inch lbs.).
^ Stage 2: Tighten an additional 85 - 95 degrees.

16. NOTE: The EGR valve is shown removed for clarity.





If equipped, connect the EGR solenoid vacuum and electrical connectors.





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





18. If equipped, install the EGR valve-to-exhaust manifold tube.
^ Hand-tighten the fittings.
^ Tighten the upper fitting to 40 - 60 Nm (30 - 44 ft. lbs.).
^ Tighten the lower fitting to 40 - 60 Nm (30 - 44 ft. lbs.).





19. If equipped, install the EGR transducer bracket.
^ Position the bracket.
^ Install the bolts.





20. If equipped, connect the vacuum lines.





21. If equipped, connect the EGR transducer and throttle position sensor electrical connectors.





22. Connect the heater hose.





23. Connect the idle air control motor bypass hose and connector.





24. Connect the five RH fuel injector electrical connectors and five RH ignition coil connectors.





25. Connect the vacuum line.





26. Install the RH radio interference capacitor.
^ Position the capacitor.
^ Install the bolt.





27. Connect the vacuum lines to the:
^ brake booster.
^ engine control sensor wiring harness.





28. Connect the PCV vacuum and coolant hoses.
29. On bi-fuel vehicles, install the compuvalve and vaporizer.





30. Install the accelerator bracket.
^ Position the bracket.
^ Install the bolts.





31. Connect the accelerator and speed control cables and return spring.





32. Install the accelerator cable splash shield.
33. Install the air cleaner outlet tube.





34. Connect the engine water outlet hose and position the hose clamp.
35. Fill the cooling system.
36. Connect the battery ground cable.