Intake Manifold: Service and Repair

Intake Manifold

Removal and Installation

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel - related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury.

1. Disconnect the battery ground cable.
2. Drain the cooling system.
3. Disconnect the fuel line from the fuel injection supply manifold.

Part 2 Of 2:

4. Illustration 1 of 7. Remove the components in the order indicated.





5. Illustration 2 of 7. Remove the components in the order indicated.





6. Illustration 3 of 7. Remove the components in the order indicated.





7. Illustration 4 of 7. Remove the components in the order indicated.





8. Illustration 5 of 7. Remove the components in the order indicated.





9. Illustration 6 of 7. Remove the components in the order indicated.

Part 1 Of 2:

Part 2 Of 2:

10. Illustration 7 of 7. Remove the components in the order indicated.
11. To install, reverse the removal procedure.
12. Fill and bleed the engine cooling system.
13. Connect the fuel line to the fuel injection supply manifold.
14. Connect the battery ground cable.

Item 3: Brake Booster Vacuum Hose Removal Note





1. Remove the brake booster vacuum tube retaining bolt and disconnect the vacuum tube.

Items 7 and 8: Throttle Cable Assembly and Speed Control Cable Removal Note





1. Disconnect the accelerator cable, the speed control cable and the return spring from the throttle body and the bracket, and position the cables aside.

Item 12: Engine Wiring Harness Removal Note





1. Disconnect the fuel rail ground wire.





2. Disconnect the Idle Air Control (IAC) and the Throttle Position (TP) sensor electrical connectors.





3. Disconnect the differential pressure feedback EGR system electrical connector.





4. Disconnect the eight fuel injector electrical connectors.





5. Separate the wire harness locators and the knock sensor electrical connector from the back of the intake manifold.

Item 34: Intake Manifold Bolts Installation Note





1. Tighten the retaining bolts in the sequence shown.

Item 12: Engine Wiring Harness Installation Note





1. Separate the wire harness locators and the knock sensor electrical connector from the back of the intake manifold.





2. Disconnect the eight fuel injector electrical connectors.





3. Disconnect the differential pressure feedback EGR system electrical connector.





4. Disconnect the Idle Air Control (IAC) and the Throttle Position (TP) sensor electrical connectors.





5. Disconnect the fuel rail ground wire.

Items 7 and 8: Throttle Cable Assembly and Speed Control Cable Installation Note





1. Connect the accelerator cable, the speed control cable and the return spring to the throttle body and the bracket.

Item 3: Brake Booster Vacuum Hose Installation Note





1. Connect the brake booster vacuum tube and install the retaining bolt.