Intake Manifold: Service and Repair

Removal
1. Drain the cooling system.
2. Remove the air cleaner outlet tube.





3. Disconnect the vacuum hoses at the (1) fuel pressure regulator and the (2) intake manifold.





4. Disconnect the vacuum lines from the (1) exhaust recirculation valve, the (2) positive crankcase ventilation valve, and the (3) idle air control valve.





5. Disconnect the (1) speed control cable (if equipped), the (2) accelerator cable, and the throttle control lever.





6. Remove the bolt.





7. Disconnect the (A) Idle Air Control (IAC) valve and the (B) Throttle Position (TP) sensor electrical connectors.





8. Remove the oil level indicator tube bracket bolt from the intake manifold.





9. Disconnect the EGR manifold tube located just below the EGR valve.
10. Raise and support the vehicle.





11. Remove the oil level indicator tube from the cylinder block.





12. Remove the nuts.
13. Lower the vehicle.





14. Remove the nuts and remove the intake manifold, Discard the gasket.

Installation

1. CAUTION: Do not use abrasive grinding discs to remove the gasket material; use only manual scrapers. Do not scratch or gouge aluminum sealing surfaces.

Clean and inspect the mounting faces of both the intake manifold and the cylinder head. Both surfaces must be clean and flat.
2. Clean and oil the manifold studs.





3. Install the gasket and the intake manifold. Hand-tighten the nuts.
4. Raise and support the vehicle.





5. Install the nuts.





6. Install the oil level indicator tube.
7. Lower the vehicle.





8. Tighten the nuts.





9. Install the EGR manifold tube.





10. Install the bolt.





11. Connect the (A) IAC valve electrical and the (B) throttle position sensor connectors.





12. Install the speed control cable bracket and bolt.





13. Connect the (1) speed control cable and the (2) accelerator cable to the throttle control lever.





14. Connect the vacuum hoses to the (1) fuel pressure regulator and the (2) intake manifold.





15. Connect the vacuum lines to the (1) exhaust recirculation valve, the (2) positive crankcase ventilation valve, and the (3) idle air control valve.
16. Install the air cleaner outlet tube.
17. Refill the engine cooling system.
18. Start the engine and check for coolant leaks.