Intake Manifold: Service and Repair

REMOVAL
1. Disconnect negative battery terminal and set aside.
2. Drain engine cooling system.
3. Remove PCV closure hose from rocker arm cover and clean air flex tube.
4. Remove clean air flex tube from throttle body and air cleaner.
5. Carefully relieve fuel pressure at fuel supply manifold schrader valve.
6. Remove fuel line safety clips. Disconnect fuel lines.

CAUTION: Cover the valve with a shop rag to prevent accidental fuel spray into the eyes.

7. Mark location of vacuum lines and remove.
8. Disconnect Air Charge Temperature (ACT), secondary air injection bypass valve, bypass air, Idle Speed Control (ISC), Engine Coolant Temperature (ECT), distributor, ignition coil and coolant temperature sending unit electrical connectors.
9. Disconnect upper radiator hose from thermostat housing. After loosening retaining clamp, use a twisting motion on hose to loosen from housing.
10. Remove ignition control module (two nuts) from top of throttle body.
11. Remove brace spanning from alternator bracket to throttle body stud.
12 Remove throttle body.
13. Disconnect fuel injector harness retaining stand-offs from inboard rocker arm cover studs. Carefully disconnect electrical connections to each injector and remove harness from engine.
14. Disconnect heater hoses.
15. Remove ignition wires from spark plugs by using a twisting motion on the rubber boot. Remove harness retaining standoffs from rocker arm cover studs.
16. Mark distributor housing to block and note rotor position. Remove distributor retaining bolt and washer. Remove distributor.
17. Remove rocker arm covers.
18. Loosen cylinder No. 3 intake valve rocker arm retaining nut and rotate arm off push rod and away from top of valve stem. Remove push rod.
19. Remove intake manifold retaining bolts using a Torx head socket. Before attempting to remove intake manifold, break the seal between the manifold and cylinder block. Wedge a large screwdriver or similar heavy duty tool between the manifold and the block. Pry upward on the tool using the lug on top of the front cover as a leverage point. Removal of alternator may be required for this step. Use care to prevent damage to machined surfaces.

NOTE: Manifold assembly may be removed with fuel supply manifold and injectors in place.

INSTALLATION

NOTE: Lightly oil all retaining bolt and stud threads before installation.

1. Clean mating gasket surfaces of intake manifold and cylinder head. Lay a clean cloth or shop rag in the tappet valley to catch any gasket material. After scraping, carefully lift cloth from tappet valley preventing any particles from entering oil drain holes or cylinder head. Use a suitable solvent to remove old rubber sealant.

CAUTION: Aluminum components gouge easily which cause gasket leaks. Always use care when scraping aluminum gasket surfaces.

Fuel Rail And Injector Assembly:

2. If installing a new intake manifold, transfer fuel injectors, fuel supply manifold, ECT sensor, thermostat, gasket and housing, heater hose elbow and coolant temperature sending unit to new manifold.

Intake Manifold Cylinder Block Seal:

3. Apply a 5-6 mm drop of Rubber Sealer D6AZ-19562-AA or -BA or equivalent to intersection of cylinder block and cylinder head assembly at four corners as shown in the illustration.

Intake Manifold Seal:

4. Position intake gaskets onto cylinder heads. Align the intake gasket locking tabs to the provisions on the cylinder head gaskets.
5. Install front and rear intake manifold seals. Secure with retaining features.

Intake Manifold Torque Sequence:

6. Carefully lower intake manifold into position aligning manifold bolt holes to those in the cylinder head. Use care to prevent disturbing the rubber sealer which can cause sealing voids. Install bolts 1, 2, 3 and 4 and hand-snug. Install remaining bolts and torque in a two-step process. Tighten in numerical sequence to 15 Nm (11 ft lb), then again to 26 Nm (19 ft lb).

NOTE: Lightly oil all retaining bolt and stud threads before installation.

7. Completely coat distributor gear teeth with ESP-M2C154-A or equivalent heavy weight gear lube. Install distributor and align to premarked location on cylinder block and rotor position. Install retaining bolt and washer and hand-snug.

NOTE: Do not add any of the ESP-M2C154-A directly to the engine oil.

8. Apply ESE-M2C39-F oil to cylinder No. 3 intake valve push rod and rocker arm. Install push rod. Move rocker arm into position with push rod and snug retaining bolt. Rotate crankshaft to position camshaft lobe straight down and away from valve lifter. Tighten retaining bolt to 11 Nm (8 ft lb) to seat rocker arm fulcrum into cylinder head. Final-tighten bolt to 32 Nm (24 ft lb) in any position.

NOTE: Fulcrum must be fully seated into cylinder head and push rod must be fully seated in rocker arm and lifter sockets prior to final tightening.

9. Install rocker arm covers and torque bolts to 12 Nm (9 ft lb).
10. Install fuel injector electrical harness to each injector. Secure with stand-offs to inboard rocker arm cover studs.
11. Connect electrical connector to coil.
12. Install distributor cap and ignition wires. Install wire harness stand-offs to rocker arm cover studs and connect wires to spark plugs and ignition coil.

Coil Assembly:

13. Install throttle body assembly and new gasket. Install ignition control module. Tighten retaining nuts to 18 Nm (13 ft lb).
14. Install fuel lines to fuel supply rail.
15. Install fuel line safety clips.
16. Install upper radiator hose and heater hoses. Tighten retaining clamps securely.
17. Connect vacuum lines to premarked locations.
18. Connect electrical connections to ACT, secondary air injection bypass valve, bypass air, ISC, ECT, distributor, ignition coil and coolant temperature sending unit.
19. Fill and bleed cooling system with specified coolant and proper mixture.
20. Replace crankcase oil.

NOTE: Engine coolant is corrosive to all engine bearing material. Replacing oil after removal of a coolant carrying component prevents failure later.

21. Install clean air flex tube to throttle body and air cleaner. Tighten retaining clamps to 1.9 Nm (16 in lb).
22. Install PCV closure hose to rocker arm cover and clean air flex tube provisions.
23. Connect negative battery terminal.

NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

24. Start engine and check for coolant, oil, fuel and vacuum leaks.
25. Verify and correct default base initial engine timing to 10 degrees BTDC. Tighten retaining bolt to 24 Nm (18 ft lb).