Intake Manifold: Service and Repair

Fig. 2 Intake Manifold Bolt Tightening Sequence:

1. Disconnect battery ground cable.
2. Drain cooling system.
3. Remove throttle body to intercooler intermediate cooler pipe.
4. Disconnect radiator and coolant by-pass hoses at intake manifold.
5. Disconnect coolant inlet and outlet hoses at throttle body.
6. Disconnect and tag electrical connectors form intake manifold mounted components.
7. Remove EGR valve and EGR vacuum control and bracket.
8. Disconnect PCV breather tube.
9. Disconnect power brake unit vacuum hose.
10. Disconnect and tag intake manifold vacuum hoses.
11. Disconnect control cables from throttle body.
12. Disconnect heater inlet and outlet pipes.
13. Disconnect ignition wires from coil unit, then remove coil unit.
14. Relieve fuel system pressure as described under MAINTENANCE PROCEDURE/RELIEVING FUEL SYSTEM PRESSURE.
15. Disconnect fuel lines at fuel rail and pressure regulator.
16. Remove intake manifold attaching bolts and intake manifold.
17. Reverse procedure to install. apply sealer 12345336 or equivalent to ends of intake manifold seal. When installing intake manifold attaching bolts, tighten bolts, Fig. 2, positions 1 and 2 until snug, then tighten all bolts in sequence shown in Fig. 2.