Intake Manifold Replacement (On Vehicle)
REMOVAL PROCEDURE
1. Relieve the fuel pressure.
2. Disconnect the negative battery cable.
3. Drain the engine coolant.
4. Remove the air cleaner assembly.
5. Disconnect the following electrical connectors:
^ The ground wires from the intake manifold
^ The fuel injector connector
^ The manifold absolute pressure (MAP) sensor connector
^ Throttle Position (TP) Sensor
^ Idle Air Control (A/C) Valve
^ EVAP Canister Purge Valve
6. Disconnect the wiring harness from the retaining clamps.
7. Remove the coolant hoses from the throttle body (8) and intake manifold.
8. Remove the following hoses:
^ The canister purge hose from the intake manifold
^ The brake booster hose from the intake manifold
9. Remove the accelerator cable from the throttle body.
10. Remove the seven nests and three bolts from the intake manifold.
11. Remove the intake manifold (6) with the throttle body (8) and the wire clamps from the cylinder head still attached.
12. Remove the intake manifold gasket from the cylinder head.
INSTALLATION PROCEDURES
1. Install the new intake manifold gasket to the cylinder head.
2. Install the intake manifold with the TBI unit (8) and wire clamps to the cylinder head still attached. Secure the intake manifold with the two nuts and the seven bolts.
^ Tighten the intake manifold mounting bolts an nuts to 23 Nm (17 ft. lbs.).
3. Install the following vacuum hoses:
^ The canister purge hose to the intake manifold
^ The brake booster hose from the intake retrained
4. Install the coolant hoses to the throttle body and the intake manifold.
5. Install the fuel return and the fuel feed hoses to the throttle badly
6. Connect the following electrical connectors:
^ The ground wires front the intake manifold
^ The fuel injector connector
^ The manifold absolute pressure (MAP) sensor connector
^ Throttle Position (TP) Sensor
^ Idle Air Control (IAC) Valve
^ EVAP Canister Purge Valve
7. Secure the wiring harness to the retaining clamps.
8. Install the accelerator cable to the throttle body.
9. Adjust the accelerator cable to the specifications.
10. Install the air cleaner assembly to the throttle body.
11. Reconnect the negative battery cable.
12. Refill the cooling system.
13. Upon completion of the installation, start the engine and check fuel and engine coolant leaks.