Intake Manifold: Service and Repair
MANIFOLD - INTAKEREMOVAL
1. Perform the Fuel System Pressure Release procedure.
2. Disconnect negative cable from battery.
3. Remove air cleaner housing and throttle body resonator.
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 accessory drive belt.
8. Disconnect generator electrical connections.
9. Unbolt the generator and move it away from the intake manifold for clearance.
10. Disconnect air conditioning compressor electrical connections.
11. Unbolt the air conditioning compressor and move it away from the intake manifold for clearance.
12. Disconnect left and right radio suppressor straps.
13. Disconnect and remove ignition coil towers.
14. Remove top oil dipstick tube retaining bolt and ground strap.
15. Remove fuel rail.
16. Remove throttle body assembly and mounting bracket.
17. Drain cooling system below coolant temperature level.
18. Remove intake manifold retaining fasteners, in reverse order of tightening sequence.
NOTE: Intake must be lifted upward and level in the front and rear to clear the cowl. Interference with the cowl will occur during removal.
19. Remove intake manifold.
CLEANING
NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.
Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.
INSPECTION
1. Inspect the intake sealing surface for cracks, nicks and distortion.
2. Inspect the intake manifold vacuum hose fittings for looseness or blockage.
3. Inspect the manifold to throttle body mating surface for cracks, nicks and distortion.
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. Install throttle cable bracket.
7. Connect throttle cable and speed control cable to throttle body.
8. Install fuel rail.
9. Install ignition coil towers.
10. Install coolant temperature sensor.
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 including electrical connections.
14. Connect Vapor purge hose, Brake booster hose, Speed control servo hose, Positive crankcase ventilation (PCV) hose.
15. Install air conditioning compressor including electrical connections.
16. Fill cooling system.
17. Install accessory drive belt.
18. Install air cleaner housing and throttle body resonator. Tighten resonator bolts 5 Nm (44 inch lbs.).
19. Connect negative cable to battery.