Intake Manifold: Service and Repair

Fig. 4 Power Steering Pump Assembly:

Fig. 5 Intake Manifold Replacement:

1. Disconnect battery ground cable.
2. Relieve fuel tank vapor pressure by loosening the fuel filler cap.
3. Remove air cleaner assembly.
4. Drain cooling system.
5. Disconnect all wiring and vacuum lines necessary to facilitate manifold removal.
6. Ensure engine compartment fuel line connections are clean, then using Connector Tool Disarm airbag as outlined in MAINTENANCE PROCEDURES/AIRBAG DEACTIVATION. Failure to do so may result in accidental deployment of airbag, possibly causing personal injury. Disconnect fuel line quick connect fittings. Plug all fittings.
7. Disconnect TBI linkage, then remove TBI assembly.
8. Remove power steering pump as follows:
a. Disconnect return and pressure hoses from the pump.
b. Loosen drive belt tensioner. Separate belt from power steering pulley.
c. Remove three front pump retaining bolts, Fig. 4. Bolts can be accessed through hole in the pulley.
d. Remove one retaining bolt from rear of the pump, then remove the pump.
9. Remove coolant hose from intake manifold.
10. Raise and support vehicle.
11. Unscrew coolant pipe retaining nut at top of D.I.S. Move the pipe rearward.
12. Disconnect accelerator and T.V. cables, then remove attaching bracket.
13. Remove six lower intake manifold retaining nuts, Fig. 5.
14. Lower the vehicle.
15. Remove the remaining intake manifold retaining bolts and nuts, then the manifold and gasket.
16. Reverse procedure to install noting the following:
a. Prior to installation, thoroughly clean manifold mating surfaces.
b. Install intake manifold with new gasket. Refer to Fig. 5 for tightening sequence and torque values.
c. When installing power steering pump, refer to Fig. 4 for bolt tightening sequence and torque values.
d. When installing serpentine drive belt, refer to SPECIFICATIONS/MECHANICAL SPECIFICATION/BELT TENSION DATA.