Intake Manifold: Service and Repair
INTAKE MANIFOLD REMOVAL/INSTALLATIONRemoval
1. Drain the engine cooling system.
2. Remove the accelerator control snow shield.
3. Remove the air cleaner outlet tube. See AIR CLEANER OUTLET PIPE REMOVAL/INSTALLATION.
4. Disconnect the throttle cables from the intake manifold.
1. Disconnect the accelerator cable and cruise control cable (if so equipped) from the throttle linkage.
2. Disconnect the accelerator cable and cruise control cable (if so equipped) from the mounting bracket.
5. Disconnect the throttle position (TP) sensor.
6. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
7. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.
8. Disconnect the engine vacuum harness, brake booster hose, and the crankcase breather hose. Disconnect the coolant hoses.
9. Disconnect two engine wiring harness pin-type retainers from the intake manifold.
10. Disconnect the pin-type retainer from the rear of the intake manifold.
11. Remove the electric EGR (EEGR) tube bracket bolt.
12. Disconnect the fuel line from the clip.
13. Remove the bolts from the EEGR tube flange.
14. Detach the 42-pin electrical connector from the bracket and disconnect the intake vacuum hose.
15. Disconnect the engine knock sensor (KS) electrical connector and disconnect the connector from the intake manifold.
16. Remove the wiring harness push pin from the bottom of the intake manifold.
17. Remove the bracket.
18. Disconnect fuel supply tube from the manifold. For additional information, See FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR REMOVAL/INSTALLATION.
NOTE: Engine removed for clarity.
19. Remove the five bolts and the intake manifold.
Installation
1. Inspect and install new intake manifold gaskets, if necessary.
NOTE: Engine removed for clarity.
2. Install the intake manifold and the five mounting bolts.
3. Connect the wiring pushpin to the bottom of the intake manifold
4. Connect the engine KS connector to the intake manifold and connect the electrical connector.
5. Attach the 42-pin electrical connector to the bracket and connect the intake vacuum hose.
6. Install the EEGR flange mounting bolts.
7. Connect the fuel line into the clip.
8. Install the EEGR tube bracket bolt
9. Install the bracket.
10. Position back the engine wiring harness and connect the pushpin.
11. Connect the engine vacuum harness, brake booster hose and the crankcase breather hose. Connect the coolant hoses.
12. Connect the vapor purge hose and the IAC valve electrical connector.
13. Connect the MAP sensor electrical connector.
14. Connect the throttle position sensor.
15. Connect the throttle cables to the intake manifold and the throttle body.
1. Connect the accelerator cable and cruise control cable (if so equipped) into the mounting bracket.
2. Connect the accelerator cable and cruise control cable (if so equipped) onto the throttle linkage.
16. Install the air cleaner outlet tube. See AIR CLEANER OUTLET PIPE REMOVAL/INSTALLATION.
17. Install the accelerator control snow shield.
18. Fill and bleed the engine cooling system.