Intake Manifold: Service and Repair

Upper Intake Manifold:

REMOVAL

1. Disconnect electrical connectors at air bypass valve, throttle position sensor and air charge temperature sensor (ACT).
2. Remove snow/ice shield to expose throttle linkage. Remove throttle cable bracket and disconnect cable from throttle body ball stud.
3. Remove air inlet tube from air cleaner to throttle body.
4. Disconnect upper intake manifold vacuum connectors.
5. Disconnect PCV valve from rocker cover.
6. Disconnect spark plug wires from comb at rear of manifold.
7. Remove canister purge line from throttle housing fitting.
8. Remove bolt retaining A/C line at upper rear of manifold.
9. Remove six upper intake manifold retaining bolts.
10. Remove upper intake and throttle body as an assembly.

INSTALLATION

1. Clean and inspect manifold mounting surfaces.
2. Position new gasket on mounting studs.
3. Install upper intake manifold on studs.
4. Install six upper intake manifold retaining nuts. Torque nuts to 15 - 18 ftlb (20 - 25 Nm).
5. Connect plug wires to retainer comb at rear of manifold.
6. Attach A/C line retainer and automatic transmission vacuum line retainer to manifold.
7. Install canister purge line on throttle body fitting.
8. Connect vacuum lines to vacuum tree. Plug in electrical connectors at air bypass valve, TP sensor, and ACT sensor.
9. Install PCV valve in grommet at rear of right rocker cover.
10. Attach throttle cable bracket to manifold, then connect cable to ball stud and install snow/ice shield.

NOTE: If lower intake manifold was removed, fill and bleed cooling system.