Intake Manifold: Service and Repair
Removal1. Disconnect the battery ground cable.
2. Relieve the fuel system pressure.
3. Remove the interior engine cover.
4. Drain the cooling system.
5. Remove the engine Air Cleaner (ACL) and the air cleaner outlet tube.
6. Compress and slide the hose clamp and disconnect the upper radiator hose.
7. Remove the accelerator cable snow shield.
8. Note: Typical is shown.
Disconnect the throttle body cam.
1. Disconnect the accelerator cable.
2. Disconnect the speed control actuator cable.
3. Remove the throttle return spring.
9. Note: Typical is shown.
Remove the bolts retaining the accelerator cable bracket and position the bracket aside.
10. Remove the bolt and position the accelerator and speed control cables aside.
11. Note: Typical is shown.
Disconnect the throttle position sensor electrical connector.
12. If equipped, disconnect the auxiliary heater hoses.
13. Disconnect the idle air control valve fresh air hose.
14. Disconnect the Engine Vacuum Regulator (EVR) valve connections.
15. Disconnect the vapor management valve hose and vacuum line.
16. Remove the two vapor management valve nuts and position the valve aside.
17. Disconnect the idle air control valve electrical connector.
18. Disconnect the brake booster and main vacuum harnesses.
19. Disconnect the EGR vacuum line.
20. Position the EGR valve to exhaust manifold tube aside.
^ Disconnect the upper fitting.
^ Disconnect the hoses.
^ Loosen the lower fitting.
^ Position the tube aside.
21. Disconnect the differential pressure feedback EGR connector.
22. Remove the differential pressure EGR bracket bolts.
23. Disconnect the fuel lines.
24. Remove the four bolts and the throttle body and adapter as an assembly.
25. Disconnect the fuel pressure regulator vacuum line.
26. Remove the generator.
27. Disconnect the water temperature sensor connector.
28. Disconnect the heater hose.
29. Remove the heater hose bracket.
30. Disconnect the PCV hose.
31. Disconnect the eight fuel injector connectors.
32. Disconnect and remove the eight ignition coils.
33. Remove the water thermostat.
34. Remove the nine bolts.
35. Remove the intake manifold.
^ Discard the intake manifold gaskets.
36. If required, remove the six bolts and the water crossover.
37. Clean and inspect the water crossover gaskets. Install new gaskets if required.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or any other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which may leak paths. Use a plastic scraping tool to clean these surfaces.
Clean and inspect all sealing surfaces.
2. If removed, install the water crossover.
3. Position the new intake manifold gaskets and the intake manifold, loosely install the nine bolts.
4. Install the water thermostat and housing.
^ Loosely install the bolts.
5. Tighten the 11 bolts in two stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
6. Install and connect the eight ignition coils.
7. Connect the eight fuel injector electrical connectors.
8. Connect the PCV hose.
9. Install the heater hose bracket.
10. Connect the heater hose.
11. Connect the water temperature sensor electrical connector.
12. Install the generator.
13. Connect the fuel pressure regulator vacuum line.
14. Install the throttle body and adapter as an assembly. Tighten the bolts in two stages.
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten an additional 90 degrees.
15. Connect the fuel lines.
16. Install the differential pressure EGR bracket.
17. Connect the differential pressure feedback EGR electrical connector.
18. Connect the EGR valve to exhaust manifold fittings.
^ Tighten the fittings starting at the top in two stages.
^ Stage 1: Hand-tighten the fittings.
^ Stage 2: Tighten to 40 - 60 Nm (30 - 44 ft. lbs.).
^ Connect the vacuum lines.
19. Connect the EGR vacuum line.
20. Connect the idle air control valve electrical connector.
21. Install the vapor management valve.
22. Connect the hoses.
23. Connect the EVR connections.
24. Connect the IAC fresh air hose.
25. If equipped, connect the auxiliary heater hoses.
26. Note: Typical is shown.
Connect the throttle position sensor electrical connector.
27. Install the accelerator cable routing bracket.
28. Note: Typical is shown.
Install the accelerator cable bracket.
29. Note: Typical is shown.
Connect the throttle controls.
^ Install the throttle return spring (3).
^ Connect the speed control actuator cable (2).
^ Connect the accelerator cable (1).
30. Install the accelerator cable snow shield.
31. Connect the upper radiator hose.
32. Install the air cleaner outlet tube and the engine air cleaner.
33. Install the interior engine cover.
34. Connect the battery ground cable.
35. Fill and bleed the engine cooling system.