Intake Manifold: Service and Repair

REMOVAL




1. Disconnect intake air temperature (IAT) sensor connector.
2. Loosen clamp at air cleaner assembly.
3. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
4. Loosen clamp at throttle body assembly.
5. Disconnect PVC fresh air vent hose at outlet duct assembly.
6. Remove outlet resonator/duct assembly.

NOTE: The mating surfaces between the throttle body to manifold and manifold to cylinder head should be free from dirt and foreign material before servicing.




7. Cover throttle body opening with a shop towel, and use shop air to remove any dirt at the base of the throttle body to intake and intake manifold to cylinder head.




8. Disconnect harness connector at throttle body.




9. Remove throttle body bolts. (Throttle body removal is not required if only gasket is being replaced.)
10. Remove throttle body.

NOTE: The throttle body-to-manifold gasket is reusable if it is not damaged. If gasket is removed from groove, the gasket should be replaced.

11. Inspect gasket for cuts, nicks or swelling. Replace if any of the above conditions are observed.

NOTE: Cover the intake manifold opening with a shop towel whenever the throttle body is removed to prevent foreign material from entering into intake manifold.




12. Block intake manifold opening with a clean shop towel to prevent dirt from entering.




13. Remove engine control module (ECM) bolts and set ECM aside.
14. Disconnect electrical connectors (injector harness) attach to side of manifold and position harness away from manifold and set aside.
15. Disconnect manifold absolute pressure (MAP) sensor.
16. Disconnect purge hose.
17. Disconnect electrical attachment bolt at bottom of manifold.
18. Raise vehicle.
19. Disconnect electrical harness clips at bottom of manifold.
20. Lower vehicle.




21. Remove oil level tube bolt and rotate tube away from manifold.
22. Remove intake manifold bolts and nuts.
23. Pull manifold away from cylinder head.




24. Disconnect brake booster hose at manifold by releasing white tab.
25. Remove intake manifold assembly.

NOTE: The intake manifold gasket is reusable if not damaged. If gasket is removed from groove, the gasket should be replaced.




26. Inspect gasket for cuts, nicks or swelling. Replace if any of the above condition are observed.

NOTE: Cover the cylinder head ports with a shop towel to prevent foreign material from entering cylinder head

27. Block intake manifold to cylinder head openings with a clean shop towel to prevent dirt from entering.

INSTALLATION
1. Remove shop towel from throttle body opening.
2. Install intake manifold gasket to manifold if necessary.




3. Connect brake booster hose to intake manifold.
4. Install intake manifold to cylinder head.
5. Install intake manifold bolts and nuts.

Torque:
Intake Manifold-to-Cylinder Head Bolts - L61: 10 N.m (89 in lbs)
Intake Manifold-to-Cylinder Head Nuts - L61: 10 N.m (89 in lbs)




6. Install oil level indicator tube assembly and bolt.

Torque:
Oil Level Indicator Tube-to-Intake Manifold Bolt - L61: 10 N.m (89 in. lbs.)




7. Install ECM assembly and bolts.
8. Attach electrical harness to bottom of intake manifold.
9. Connect electrical connector at ECM, injector harness and MAP sensor.




10. Connect purge hose.
11. Remove shop towel from throttle body opening.




12. Install throttle body gasket if necessary.
13. Install throttle body assembly and bolts.
14. Tighten throttle body bolts.

Torque:
Throttle Body-to-Intake Manifold Bolts-L61: 10 N.m (89 in. lbs.)




15. Connect throttle body electrical connector.




16. Position outlet resonator/duct assembly into position.
17. Connect PCV fresh air vent hose assembly.
18. Tighten clamp at throttle body assembly.
19. Position outlet resonator/duct assembly up with support bracket and install push-pin.




20. Tighten clamp at air cleaner assembly.
21. Connect intake air temperature (IAT) sensor connector.