Intake Manifold: Service and Repair

Removal

1. Remove the intake manifold cover.

2. Remove the vacuum hoses (A) and breather pipe (B), then remove the intake air duct (C).

3. Remove the throttle cable (A) and cruise control cable (B) by loosening the locknuts (C), then slipping the cable ends out of the accelerator linkage. Take care not to bend the cables when removing them. Always replace any kinked cable with a new one.
4. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
- Intake air temperature (IAT) sensor connector
- Idle air control (IAC) valve connector
- Throttle position (TP) sensor connector
- Manifold absolute pressure (MAP) sensor connector
- Evaporative emission (EVAP) canister purge valve connector

5. Remove the brake booster vacuum hose (A) and positive crankcase ventilation (PCV) hose (B).

6. Remove the water bypass hoses (A), then plug the water bypass hoses.
7. Remove the EVAP canister hose (B).

8. Remove the upper cover (A), then remove the intake manifold (B) and spacer (C).

Installation
1. Put the gasket and spacer on the injector base.

2. Install the intake manifold. Tighten the bolts and nuts sequentially in two or three steps. Always use a new intake manifold gasket.

3. Install the upper cover. Tighten the bolts and nuts sequentially in two or three steps. Always use a new gasket.

4. Install the water bypass hoses (A) and EVAP canister hose (B).

5. Install the brake booster vacuum hose (A) and PCV hose (B).
6. Install the throttle cable, then adjust the cable.
7. Install the cruise control cable, then adjust the cable.

8. Install the intake air duct (A), then install the vacuum hoses (B) and breather pipe (C).

9. Install the intake manifold cover.
10. Clean up any spilled engine coolant.
11. After installation, check that all tubes, hoses and connectors are installed correctly.
12. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.