63. Intake Manifold Clean and Inspect

Cleaning Procedure





1. Remove any remaining gasket and/or gasket material from the following:
^ Throttle body
^ Throttle body adapter heater plate
^ Intake manifold
2. Clean the following intake manifold areas in solvent.
^ Intake manifold gasket grooves
^ Intake manifold passages
^ Brake booster hose passage
^ EVAP solenoid passage
^ PCV vacuum hose passages
^ MAP sensor passage
^ Throttle body adapter heater plate

Caution: Wear safety glasses in order to avoid eye damage.

3. Dry the intake manifold and throttle body adapter heater plate with compressed air.

Inspection Procedure
1. Inspect the intake manifold for the following conditions:
^ Damage to the fuel rail mounting tabs (1)
^ Damage, debris or restrictions to the MAP sensor mounting port (2)
^ Damage, debris or restrictions to the brake vacuum booster hose port (3)
^ Damage to the throttle body/throttle body adapter heater plate fastener inserts (4)
^ Damage to the EGR pipe fastener inserts (5)
^ Damage, debris or restrictions to the PCV system hose ports (6)





2. Inspect the intake manifold for the following conditions:
^ Damage to the intake manifold bolt bosses (1)
^ Damage to the EVAP purge solenoid fastener insert (2)
^ Damage, debris or restrictions to the EVAP purge solenoid port (3)
^ Damage, debris or restrictions in the vacuum passage (4)





3. Inspect the intake manifold for the following conditions:
Damage to the pressure relief valve (1)





4. Inspect the intake manifold for the following conditions:
^ Gouges or damage to the intake manifold sealing groove (1)
^ Damage to the gasket sealing surface for the throttle body adapter heater plate (2)
^ Damage to the fuel injector ports (3)





5. Inspect the throttle body adapter heater plate for the following conditions:
^ Damage to the gasket sealing surface for the intake manifold and the throttle body (1)
^ Damage, corrosion or restriction to the vacuum passage (2)
^ Damage, corrosion or restriction to the engine coolant passage (3)
^ Damage, corrosion or restrictions to the engine coolant inlet (4) and outlet (5) pipes
^ Damage to the bolt holes (6)
^ Damage to the throttle body adapter heater plate fasteners (7)
6. Inspect the intake manifold cylinder head deck for warpage.
6.1. Locate a straight edge across the intake manifold cylinder head deck surface.
6.2. Insert a feeler gauge between the intake manifold and the straight edge.
An intake manifold with warpage in excess of 0.5 mm (0.020) must be replaced.
7. Repair or replace the intake manifold and/or throttle body adapter heater plate as necessary.