Intake Manifold Replacement

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

1. Disconnect negative cable from battery.
2. Remove fuel filler cap.

Figure 19:

3. loosen wing nut on intake and remove fresh air inlet duct (Fig. 19).
4. Perform fuel bleed procedure before attempting any repairs. Refer to Powertrain Management for procedure.

WARNING: WRAP SHOP TOWELS AROUND FUEL HOSE TO CATCH ANY GASOLINE SPILLAGE.

5. Disconnect the fuel supply line quick connect at the fuel tube assembly.

Figure 20:

6. Disconnect the coolant temperature sensor (Fig. 20).
7. Disconnect heater hose from intake manifold.
8. Disconnect heater tube from bottom of intake manifold.
9. Disconnect upper radiator hose and coolant recovery hose.
10. Remove fuel rail assembly attaching screws and remove fuel rail assembly from engine. Cover injector holes with suitable covering.

CAUTION: Do not set fuel injectors on their tips, damage may occur to the injectors

11. Remove accelerator, kickdown and speed control cables from throttle lever and bracket.

Figure 21:

12. Disconnect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors (Fig. 21).
13. Disconnect vacuum hoses from throttle body.
14. Remove throttle body.

Figure 22:

15. Disconnect Manifold Absolute Pressure/Intake Air Temperature sensor (TMAP) electrical connector. Disconnect vapor and brake booster hoses (Fig. 22)

Figure 23:

16. Disconnect knock sensor electrical connector and disconnect wiring harness from tab located on the heater tube (Fig. 23).
17. Disconnect wiring from starter.

Figure 24:

18. Remove EGR tube bolts at the valve and at the intake manifold. Remove tube from engine (Fig.24).
19. Remove intake manifold fasteners. Remove intake manifolds (upper and lower).

INSTALLATION
Before installing manifolds. Clean all mating surfaces. Replace all gaskets, with new.

Figure 25:

1. Assemble lower manifold to upper (if separated) and tighten bolts in sequence shown (Fig. 25), to 28 Nm (250 inch lbs.).

Figure 26:

2. Install intake manifold onto cylinder head and tighten fasteners to 28 Nm (250 inch lbs.) in sequence shown (Fig. 26).
3. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 inch lbs.).
4. Connect PCV and brake booster hoses.
5. Inspect quick connect fittings for damage, replace if necessary. Apply a light amount of clean engine oil to fuel inlet tube. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
6. Connect heater tube and hose to intake manifold.
7. Connect upper radiator hose and coolant recovery hose.
8. Connect coolant temperature sensor wiring connector.
9. Install throttle body. Tighten fastener to 22 Nm (200 inch lbs.).
10. Connect Manifold Absolute Pressure/Intake Air Temperature Sensor (TMAP) wiring connector.
11. Connect knock sensor connector and starter wires. Connect wiring harness to heater tube tab.
12. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.
13. Connect vacuum hoses to throttle body.
14. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever.
15. Install new EGR tube gaskets. Loose assemble the EGR tube onto valve and intake manifold finger tight. Tighten tube fasteners at the EGR valve first to 11 Nm (95 inch lbs.) then, tighten the intake manifold side fasteners to 11 Nm (95 inch lbs.).
16. Install fresh air duct to air filter housing. Tighten clamp to 3 Nm (25 inch lbs.).
17. Connect negative cable to battery.
18. With the DRB scan tool use ASD Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.