Intake Manifold: Service and Repair

Intake Manifold

Removal
1. Drain the engine cooling system.





2. Remove the accelerator control snow shield.
3. Remove the air cleaner outlet tube.





4. Disconnect the throttle cables from the intake manifold.
1. Disconnect the accelerator cable and speed control cable (if so equipped) from the throttle linkage.
2. Disconnect the accelerator cable and speed control cable (if so equipped) from the mounting bracket.





5. Disconnect the throttle position (TP) sensor electrical connector.





6. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.





7. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.





8. Disconnect the engine vacuum harness, brake booster hose, and the crankcase breather hose. Disconnect the coolant hoses.





9. Disconnect two engine wiring harness pin-type retainers from the intake manifold.





10. Disconnect the pin-type retainer from the rear of the intake manifold.





11. Remove the exhaust gas recirculation (EGR) tube bracket bolt.





12. Disconnect the fuel hose from the clip.





13. Remove the bolts from the EGR tube flange.





14. Detach the 42-pin electrical connector from the bracket and disconnect the vapor purge hose.





15. Disconnect the engine knock sensor (KS) electrical connector and disconnect the connector from the intake manifold.
16. Remove the wiring harness pushpin from the bottom of the intake manifold.





17. Remove the bracket.
18. Disconnect fuel supply tube from the manifold.





19. NOTE: Engine removed for clarity.

Remove the five bolts and the intake manifold.

Installation





1. Inspect and install new intake manifold gaskets, if necessary.





2. NOTE: Engine removed for clarity.

Install the intake manifold and the five mounting bolts.
3. Connect the wiring pushpin to the bottom of the intake manifold.





4. Connect the engine KS connector to the intake manifold and connect the electrical connector.





5. Attach the 42-pin electrical connector to the bracket and connect the vapor purge hose.





6. Install the EGR flange mounting bolts.





7. Connect the fuel hose into the clip.





8. Install the EGR tube bracket bolt.





9. Install the bracket.





10. Position the engine wiring harness and connect the pin-type retainers.





11. Connect the engine vacuum harness, brake booster hose and the crankcase breather hose. Connect the coolant hoses.





12. Connect the vapor purge hose and the IAC valve electrical connector.





13. Connect the MAP sensor electrical connector.





14. Connect the TP sensor electrical connector.





15. Connect the throttle cables to the intake manifold and the throttle body.
1. Connect the accelerator cable and speed control cable (if so equipped) into the mounting bracket.
2. Connect the accelerator cable and speed control cable (if so equipped) onto the throttle linkage.
16. Install the air cleaner outlet tube.





17. Install the accelerator control snow shield.
18. Fill and bleed the engine cooling system.