Intake Manifold: Service and Repair

REMOVAL
1. Relieve the fuel system pressure.
2. Disconnect the battery ground cable.
3. Drain the cooling system.
4. Remove the vacuum hoses and electrical connectors from the engine air cleaner.
5. Remove the engine air cleaner (ACL).
6. Disconnect the knock sensor (KS) electrical connector and remove the vacuum tube to intake manifold clip from the intake manifold.
7. Remove the crankshaft position sensor bracket from the rear side of the intake manifold.
8. Remove the rear spark plug wires from the spark plugs and the routing clips.





9. Remove the variable resonance induction system (VRIS) solenoid electrical connector bracket from the rear of the intake manifold.
10. Disconnect all necessary vacuum hoses from the rear of the intake manifold and EGR valve (EGR valve).
11. Disconnect the positive crankcase ventilation (PCV) valve vacuum hose from the intake manifold, near the throttle body.





12. Disconnect the throttle position (TP) sensor and the two fuel injection supply manifold electrical connectors.





13. Disconnect the accelerator cable from the throttle body.
14. Remove the accelerator cable from the accelerator cable bracket on the intake manifold.
15. Disconnect the vacuum hose from the evaporative emissions canister (EVAP canister).





16. Remove the fuel supply tube from the fuel injection supply manifold. Discard both copper crush washers.





17. Disconnect the return fuel tube and vacuum hose from the fuel pressure regulator.
18. Remove the EGR solenoid vacuum valve bracket-to-intake manifold bolt at the rear of the intake manifold.
19. Disconnect the PCV valve.
20. Remove the intake manifold nuts and intake manifold bolts in two or three steps, then remove the intake manifold.

INSTALLATION
1. To install, reverse the removal procedure.
^ Install the fuel tubes with two new copper crush washers.
^ Clean the gasket surfaces. Install the intake manifold with new intake manifold gaskets.
^ Tighten the intake manifold nuts and intake manifold bolts to 19-25 Nm (14-18 ft. lbs.).
^ Tighten the fuel supply tube bolts to 25-34 Nm (18-25 ft. lbs.).
^ Refill the cooling system with specified type and mixture of antifreeze and water.