Intake Manifold: Service and Repair

1. Release fuel pressure as outlined under Technician Safety Information.
2. Disconnect battery ground cable.
3. Remove intake manifold, noting the following:

Fig. 4 Intake Manifold Removal (Part 1 Of 2):

Fig. 4 Intake Manifold Removal (Part 2 Of 2):

a. Chalk mating marks on radiator upper hose and hose clamp, then remove hose, Fig. 4.
b. Remove fuel rail fuel injector and pressure regulator. Do not drop injector when removing fuel rail.
c. Inspect intake manifold and intake manifold plenum for defects and cracks, replace as necessary.
d. Inspect load of drain port, ensuring cooling water and jet air passages are not clogged.
e. Measure deflection of installation surface with straightedge and feeler gauge, deflection should be 0.006-0.012 inch.
4. Reverse procedure to install, noting the following
a. Align mating marks on upper radiator hose and hose clamp, then install.

Fig. 5 Radiator Hose Mating Marks:

b. Apply pressure as shown, Fig. 5, to ensure clamp is seated correctly.