Intake Manifold: Service and Repair

REMOVAL

Fuel Charging Assembly:

1. Disconnect engine air cleaner outlet tube from air intake throttle body.

Intake Manifold:

2. Unplug throttle position sensor from wiring harness.
3. Disconnect vacuum lines from upper manifold and throttle body assembly.

EGR Tube:

4. Disconnect EGR tube at manifold connection.

Manifold Support Bracket:

5. Unplug Air Bypass Valve connector.
6. Remove manifold upper support bracket top bolt.
7. Remove five upper manifold retaining bolts.
8. Remove upper manifold assembly and set it aside.
9. Remove and discard the gasket from the lower manifold assembly.

NOTE: If scraping is necessary, be careful not to damage gasket surfaces of upper and lower manifold assemblies, or allow material to drop into the lower manifold

INSTALLATION:

NOTE: For torque values refer to SPECIFICATIONS.

1. Ensure that gasket surfaces of upper and lower intake manifolds are clean.
2. Place a new service gasket on lower manifold assembly and mount upper intake manifold to lower, securing it with five retaining bolts. Tighten bolts to 15-22 lb. ft. (20-30 N-m).
3. Reconnect manifold upper support bracket. Tighten bolt to 15-22 lb. ft. (20-30 N-m).
4. Reconnect EGR tube with oil-coated compression nut. Tighten to 40-55 lb. ft. (29-40 N-m).
5. Connect electrical connectors to air bypass valve and throttle position sensor, and vacuum hoses to throttle body and upper manifold.
6. Connect engine air cleaner outlet tube to throttle body intake securing it with a hose clamp.