Intake Manifold: Service and Repair

Intake Manifold Removal and Installation

Exploded View





Removal

1. Remove the hood support rod, then use it as shown to prop the hood in the wide-open position.

2. Remove the bulkhead cover. Front Bulkhead Cover Replacement






3. Disconnect the fan motor connectors (A) and the hood switch connector (B), then remove the harness clips (C).






4. Remove the radiator upper brackets (A), then remove the front bulkhead (B).






5. Remove the intake manifold cover.






6. Disconnect the vacuum hose (A) and breather pipe (B), then remove the intake air duct (C).

7. Remove the following engine wire harness connectors and wire harness clamps from the intake manifold:
- Manifold absolute pressure (MAP) sensor connector

- Throttle actuator connector





8. Disconnect the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).

9. Remove the harness bracket mounting bolts.






10. Disconnect the water bypass hoses, then plug the water bypass hoses.

11. Raise the vehicle on the lift.






12. Remove the splash shield.






13. Remove the connector (A), then remove the intake manifold bracket (B).

14. Lower the vehicle on the lift.






15. Remove the intake manifold.






Installation

1. Install the intake manifold (A) with a new gasket (B), and tighten the bolts and nuts in a crisscross pattern in three steps, beginning with the inner bolt.

2. Raise the vehicle on the lift.






3. Install the intake manifold bracket (A), then install the connector (B).






4. Install the splash shield.

5. Lower the vehicle on the lift.






6. Install the water bypass hoses.






7. Install the EVAP canister hose (A) and the brake booster vacuum hose (B).

8. Install the harness bracket mounting bolts.

9. Connect the engine wire harness connectors, and install the wire harness clamps to the intake manifold.
- MAP sensor connector

- Throttle actuator connector





10. Install the intake air duct (A), then install the vacuum hose (B) and the breather pipe (C).






11. Install the intake manifold cover.






12. Install the front bulkhead (A), then install the radiator upper brackets (B).

13. Apply body paint to the bulkhead mounting bolts.






14. Connect the fan motor connectors (A) and the hood switch connector (B), then install the harness clips (C).

15. Install the bulkhead cover. Front Bulkhead Cover Replacement

16. Clean up any spilled engine coolant.

17. After installation, check that all tubes, hoses, and connectors are installed correctly.

18. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open. Service and Repair