Intake Manifold

Removal & Installation

CAUTION
Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the negative battery cable.
3. Relieve the fuel system pressure.
4. Drain the cooling system.
5. Remove the accelerator control snow shield.
6. Remove the air cleaner outlet tube.
7. Properly discharge the A/C system.

   NOTE: The generator will be removed with the accessory bracket.

8. Disconnect the generator wiring.
9. Disconnect the throttle cables from the intake manifold.
10. Disconnect the throttle position (TP) sensor.
11. Disconnect the manifold absolute pressure (MAP) sensor.
12. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.
13. Disconnect the engine vacuum harness, brake booster hose, and the crankcase breather hose. Disconnect the coolant hoses.
14. Disconnect the two engine wiring harness pin-type retainers from the intake manifold.
15. Disconnect the pin-type retainer from the rear of the intake manifold.
16. Remove the exhaust gas recirculation (EGR) tube bracket bolt.
17. Disconnect the fuel hose from the clip.
18. Remove the bolts from the EGR tube flange.
19. Detach the 42-pin electrical connector from the bracket and disconnect the vapor purge hose.
20. Disconnect the engine knock sensor (KS) electrical connector and disconnect the connector from the intake manifold.
21. Remove the wiring harness pushpin from the bottom of the intake manifold.
22. Remove the bracket.
23. Disconnect the fuel supply tube from the manifold.
24. Remove the five bolts and the intake manifold.

To Install:

1. Install the intake manifold and five mounting bolts.
   • Torque to 13 ft-lb (18 Nm). There is no specified torque sequence. Tighten the bolts from the center, alternating front and back to the outside.
2. Connect the fuel supply tube to the manifold.
3. Connect the wiring pushpin to the bottom of the intake manifold.
4. Connect the engine KS connector to the intake manifold and connect the electrical connector.
5. Attach the 42-pin electrical connector to the bracket and connect the vapor purge hose.
6. Install the EGR flange mounting bolts.
   • Torque to 13 ft-lb (18 Nm).
7. Connect the fuel hose into the clip.
8. Install the EGR tube bracket bolt.
   • Torque to 89 in-lb (10 Nm).
9. Install the bracket.
   • Torque to 13 ft-lb (18 Nm).
10. Position the engine wiring harness and connect the pin-type retainers.
11. Connect the engine vacuum harness, brake booster hose, and the crankcase breather hose. Connect the coolant hoses.
12. Connect the vapor purge hose and the IAC valve electrical connector.
13. Connect the MAP sensor.
14. Connect the TP sensor.
15. Connect the throttle cables.
16. Install the air cleaner outlet tube.
17. Install the accelerator control snow shield.
18. Fill and bleed the engine cooling system.
19. Properly charge the A/C system.
20. Reconnect the negative battery cable. Start the engine and allow it to reach normal operating temperature. Check for leaks and repair as necessary.