Intake Manifold: Service and Repair

Removal
1. Disconnect the battery ground cable.
2. Relieve the fuel system pressure.
3. Remove the engine cover.
4. Drain the cooling system.





5. Compress and slide the hose clamp and disconnect the upper radiator hose.
6. Remove the engine Air Cleaner (ACL) and air cleaner outlet tube.

7. Note: Typical is shown.





Disconnect the throttle body control linkage by disconnecting the (A) accelerator cable, (B) speed control actuator cable and (C) throttle control return spring.

8. Note: Typical is shown.





Remove the bolts retaining the accelerator cable bracket to the throttle body. Remove the accelerator cable bracket.

9. Note: Typical is shown.





Disconnect the connector from the Throttle Position sensor (TP sensor).

10. Note: Typical is shown.





Disconnect the following throttle body hose connections:
^ vapor management hose (A)
^ engine vacuum regulator (B)
^ Positive Crankcase Ventilation valve (PCV valve) (C)
^ power brake booster(D)





11. Remove the (A) brake booster vacuum hose bracket nut from the (B) brake booster vacuum hose bracket.
12. Disconnect the fuel lines.





13. Disconnect the following electrical connectors:
^ Differential Pressure Feedback (DPFE) transducer
^ Engine Vacuum Regulator (EVR) sensor

14. Note: Typical is shown.





Remove the EGR valve to exhaust manifold tube.
^ Disconnect the upper and lower EGR valve to exhaust manifold tube fittings.
^ Disconnect the two DPFE hoses.





15. Disconnect the following vacuum connections:
1. fuel pressure regulator vacuum hose
2. Engine Vacuum Regulator (EVR) hose
3. EGR vacuum hose
4. vapor management valve vacuum hose
16. Disconnect the PCV hoses and the PCV coolant hoses.





17. Disconnect the RH fuel injector electrical connectors.





18. Disconnect the LH fuel injector electrical connectors.
19. Disconnect and remove the eight ignition coils.
20. Remove the drive belt.
21. Remove the Generator (GEN).
22. Remove the bolts and the throttle body.





23. Disconnect the hose clamp and remove the heater water hose.





24. Remove the studs.
25. Remove the water thermostat.





26. Remove the nine bolts.





27. Remove the upper intake manifold.
1. Lift the intake manifold.
2. Disconnect the Intake Manifold Tuning Valve (IMTV) connector.
3. Remove and discard the upper intake manifold gaskets.





28. Remove the bolts.





29. Separate the upper intake manifold from the lower intake manifold and discard the lower intake manifold gasket.





30. Remove the (A) pushpin from the (B) intake manifold insulator and remove from the (C) lower intake manifold.





31. Remove the (A) bolts from the (B) intake manifold tuning valve and remove the intake manifold tuning valve.

Installation





1. Position the intake manifold tuning valve and install the bolts.





2. Install the intake manifold insulator on the lower intake manifold and install the pushpin.





3. Position the lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the eight bolts.





4. Tighten the bolts in two stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 8 - 12 Nm (71 - 106 inch lbs.).





5. Install the studs.





6. Install the upper intake manifold.
^ Position the upper intake manifold gaskets.
^ Position the upper intake manifold.
^ Loosely install the nine bolts.





7. Connect the intake manifold tuning valve connector.
8. Install the water thermostat.





9. Tighten the bolts in two stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 - 30 Nm (15 - 22 ft. lbs.).
10. Position the throttle body onto the upper intake manifold and install the bolts.





11. Install the heater water hose and position the clamp.
12. Install the generator.
13. Install the drive belt.
14. Install the eight ignition coils.





15. Connect the LH fuel injector electrical connectors.





16. Connect the RH fuel injector electrical connectors.
17. Connect the PCV hoses and the PCV coolant hoses.





18. Connect the following vacuum connections.
1. Fuel pressure regulator vacuum connector
2. Engine vacuum regulator vacuum connector
3. EGR vacuum connector
4. Vapor management valve vacuum connector

19. Note: Typical is shown.





Connect the EGR valve to exhaust manifold tube upper fitting.
Tighten both fittings starting at the top in two stages.
^ Stage 1: Hand-tighten.
^ Stage 2: Tighten to 35 - 45 Nm (26 - 33 ft. lbs.).





20. Connect the following electrical connectors:
^ EGR transducer
^ Engine vacuum regulator sensor
21. Connect the fuel lines.

22. Note: Typical is shown.





Position the brake booster vacuum hose bracket and install the nut.

23. Note: Typical is shown.





Position the accelerator cable bracket and install the bolts.

24. Note: Typical is shown.





Connect the throttle body control linkage by connecting the (A) accelerator cable, (B) speed control actuator cable and (C) throttle control return spring.
25. Install the air cleaner outlet tube and the engine air cleaner.





26. Install the upper radiator hose and reposition the clamp.
27. Fill the cooling system.
28. Install the engine cover.
29. Reconnect the battery ground cable.