Intake Manifold: Service and Repair

Removal Procedures

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.





2. Drain the cooling system.
3. Disconnect the accelerator cable from the throttle body.
4. Disconnect the Throttle Valve (TV) cable (automatic transmission).
5. Disconnect the IAT sensor connector at the air cleaner.





6. Disconnect the air cleaner hose from the throttle body (1).
7. Remove the air cleaner top assembly.
8. Disconnect the following components from the throttle body:
- The Throttle Position (TP) sensor connector
- The Idle Air Control (IAC) valve connector
- The Manifold Absolute Pressure (MAP) sensor connector
- Two coolant bypass hose clamps
- The coolant bypass hoses
9. Disconnect the four fuel injector connectors at the injectors.
10. Remove the three bolts from the fuel injector wiring harness (3,4).
11. Disconnect the wiring harness from the intake manifold.





12. Remove the following components:
- The intake manifold support bracket bolts (7)
- The intake manifold support bracket





13. Disconnect the upper radiator hose at the radiator. Move the hose to the side.
14. Remove the following fasteners:
- The upper radiator hose support bracket bolt
- The nut





15. Remove the following components from the cylinder head:
- The intake manifold bolts (2)
- The nut (1)
16. Remove the upper radiator hose support bracket.
17. Disconnect the three vacuum lines at the intake manifold.
18. Remove the two injector harness support brackets.
19. Remove the intake manifold with the throttle body from the cylinder head.

Installation Procedure
1. Install the following components to the cylinder head:
- A new intake manifold gasket
- The intake manifold with the throttle body

NOTICE: Refer to Fastener Notice in Service Precautions.





2. Use the following components in order to secure the manifold:
- Three nuts (2)
- Two bolts (1)
- Tighten the intake manifold nuts and the bolts to 18 Nm (13 ft. lbs.).

3. Install the two injector harness support brackets.
4. Connect the three vacuum lines at the intake manifold.





5. Install the upper radiator hose support bracket.
6. Connect the upper radiator hose to the radiator.





7. Install the intake manifold support bracket. Secure the bracket using two bolts (7).
- Tighten the intake manifold support bracket bolts to 18 Nm (13 ft. lbs.).





8. Install the fuel injector wiring harness. Secure the harness using three bolts (3, 4).
- Tighten the bolts to 12.7 Nm (9 ft. lbs.).

9. Connect the four fuel injector connectors to the fuel injectors.





10. Connect the following components to the throttle body:
- The Throttle Position (TP) sensor connector
- The Idle Air Control (IAC) valve connector
- The Manifold Absolute Pressure (MAP) sensor connector
- The two coolant bypass hose clamps
- The coolant bypass hoses
11. Install the air cleaner top assembly.
12. Connect the air cleaner hose (1) to the throttle body.
13. Connect the intake air temperature (IAT) sensor connector to the air cleaner.





14. Install the Throttle Valve (TV) cable (automatic transmission).
15. Install the accelerator cable to the throttle body (1).
16. Refill the cooling system as necessary.
17. Connect the negative battery cable.
- Tighten the battery cable bolt to 15 Nm (11 ft. lbs.).