Intake Manifold: Service and Repair

MANIFOLD-INTAKE

REMOVAL
1. Perform the Fuel System Pressure Release procedure.
2. Disconnect negative cable from battery.
3. Remove resonator assembly and air inlet hose.
4. Disconnect throttle and speed control cables.
5. Disconnect electrical connectors for the following components:
^ Manifold Absolute Pressure (MAP) Sensor
^ Intake Air Temperature (IAT) Sensor
^ Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor

6. Disconnect vapor purge hose, brake booster hose, speed control servo hose, positive crankcase ventilation (PCV) hose.
7. Remove the generator.
8. Remove the air conditioning compressor.
9. Disconnect left and right radio suppressor straps.
10. Disconnect and remove ignition coil towers.
11. Remove top oil dipstick tube retaining bolt and ground strap.
12. Remove fuel rail.
13. Remove throttle body assembly and mounting bracket.





14. Drain cooling system below coolant temperature level.
15. Remove the heater hoses from the engine front cover and the heater core.
16. Unclip and remove heater hoses and tubes from intake manifold.
17. Support engine using engine support fixture (1), special tool # 8534.





18. Remove the right side engine mount to frame bolt (3).
19. With the bolt removed, lower engine until engine mount rests in frame mount.





20. Remove intake manifold retaining fasteners in reverse order of tightening sequence.
21. Remove intake manifold.

INSTALLATION





1. Install intake manifold gaskets.
2. Install intake manifold.
3. Install intake manifold retaining bolts and tighten in sequence shown in to 12 Nm (105 inch lbs.).
4. Install left and right radio suppressor straps.
5. Install throttle body assembly
6. Connect throttle cable and speed control cable to throttle body.
7. Install fuel rail.
8. Install ignition coil towers.
9. Position and install heater hoses and tubes onto intake manifold.
10. Install the heater hoses to the heater core and engine front cover.
11. Connect electrical connectors for the following components:
^ Manifold Absolute Pressure (MAP) Sensor
^ Intake Air Temperature (IAT) Sensor
^ Throttle Position (TPS) Sensor
^ Coolant Temperature (CTS) Sensor
^ Idle Air Control (IAC) Motor
^ Ignition coil towers
^ Fuel injectors





12. Install top oil dipstick tube retaining bolt and ground strap.
13. Install generator.
14. Install the air conditioning compressor.
15. Connect Vapor purge hose, Brake booster hose, Speed control servo hose, Positive crankcase ventilation (PCV) hose.
16. Fill cooling system.
17. Raise engine using engine support fixture (1), special tool # 8534.





18. Install the right side engine mount to frame bolt (3).
19. Remove engine support fixture, special tool # 8534.
20. Install resonator assembly and air inlet hose.
21. Connect negative cable to battery.