Intake Manifold: Service and Repair

Fig. 5 Surge Tank & Intake Manifold. 1.5L/4-89.6 Fuel Injected Engines:

Fig. 6 Surge Tank & Intake Manifold. 2.4L/4-143.4 Engines:

FUEL INJECTED ENGINES

1. Disconnect battery ground cable, then the air intake hose from throttle body.
2. Disconnect accelerator cable and water hose, then remove throttle body, Figs. 5 and 6.
3. Disconnect PCV hose, brake booster hose and vacuum hoses.
4. Relieve fuel pressure as described under MAINTENANCE PROCEDURES/FUEL PRESSURE RELIEF, then disconnect high pressure fuel hose.
5. Remove surge tank assembly, then disconnect fuel injector harness electrical connector.
6. Remove delivery pipe with fuel injectors and pressure regulator attached.
7. Remove insulator from intake manifold, then disconnect heater hose.
8. Disconnect water temperature gauge unit and water temperature sensor assembly electrical connectors.
9. Remove water outlet fitting and thermostat, then the distributor and ignition coil.
10. Remove intake manifold stay, then the intake manifold.
11. Reverse procedure to install. Tighten nuts and bolts to specifications.