Intake Manifold: Service and Repair

Fig. 8 Surge Tank & Intake Manifold:

1. Remove idle speed actuator, Fig. 8.
2. Remove intake air hose connected to throttle body.
3. Remove accelerator cable.
4. Remove PCV hose and brake booster vacuum hoses.
5. Disconnect vacuum hose connections.
6. Disconnect high pressure fuel hose connection after relieving pressure in fuel pipe line to prevent fuel overflow.
7. Remove surge tank stay.
8. Remove surge tank assembly and gasket.
9. Disconnect fuel injector harness connector.
10. Remove delivery pipe with fuel injectors and pressure regulator attached. Be careful not to drop injectors when removing delivery pipe.
11. Remove insulator from intake manifold and disconnect heater hose.
12. Remove intake manifold.
13. Reverse procedure to install noting the following:
a. Check surge tank for defects or cracks. Replace if necessary.
b. Check intake manifold for damage or cracking of any part. Replace if necessary.
c. Check air hose for damage or cracking of any part. Replace if necessary.
d. Install delivery pipe with fuel injectors and pressure regulator attached. Be careful not to drop injectors when removing delivery pipe.
e. Ensure insulators are correctly inserted into delivery pipe hole.