Intake Manifold: Service and Repair

Intake Manifold

Material:

Removal
1. Drain the engine cooling system. For additional information, refer to Cooling System.
2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
3. Disconnect the acceleration control cable from the intake manifold and throttle body (TB).
4. If equipped, disconnect the speed control cable from the intake manifold and TB.
5. Disconnect the throttle position (TP) sensor electrical connector.
6. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
7. Disconnect the idle air control (IAC) valve electrical connector.
8. Disconnect the vapor purge tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
9. Disconnect the engine vacuum harness, brake booster hose, the crankcase breather hose and the coolant hoses.





10. Disconnect 2 engine wiring harness pin-type retainers from the intake manifold.





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





12. Remove the exhaust gas recirculation (EGR) tube support bracket bolt.
13. Remove the 2 bolts from the EGR tube flange.
14. Detach the fuel supply tube and the electrical connectors from the bracket and disconnect the vapor purge tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





15. Disconnect the knock sensor (KS) electrical connector and disconnect the connector retainer from the intake manifold.
16. Remove the wiring harness pushpin from the bottom of the intake manifold.
17. Disconnect fuel supply tube spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.

18. 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the 5 bolts and the intake manifold.
^ Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
19. Remove and discard the intake manifold gaskets.

Installation
1. Install new intake manifold gaskets.
2. Position the intake manifold and install the 5 bolts.
^ Tighten to 18 Nm (13 ft. lbs).
3. Connect the wiring pushpin to the bottom of the intake manifold.
4. Connect the KS connector retainer to the intake manifold and connect the electrical connector.
5. Attach the electrical connectors and the fuel supply tube to the bracket and connect the vapor purge tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.





6. Install the 2 EGR flange mounting bolts.
^ Tighten to 18 Nm (13 ft. lbs).
7. Install the EGR tube support bracket bolt.
^ Tighten to 10 Nm (89 inch lbs).
8. Position the engine wiring harness and connect the pin-type retainers.





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





10. Connect the IAC valve electrical connector and the fuel supply tube spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
11. Connect the MAP sensor electrical connector.
12. Connect the TP sensor electrical connector.
13. Connect the acceleration control cable to the intake manifold and the TB.
14. If equipped, connect the speed control cable to the intake manifold and the TB.
15. Install the air cleaner outlet tube. For additional information, refer to Fuel Delivery and Air Induction.
16. Fill and bleed the engine cooling system.