Originally Posted by
stanzz
anyone have write-up's on removing intake manifold?
Removal & Installation
- Properly relieve the fuel system pressure.
- Disconnect the negative battery cable.
- Drain the cooling system.
- Disconnect the intake air temperature (IAT) sensor connector.
- Disconnect the air intake assembly from the throttle body.
- Disconnect the idle air control (IAC) valve connector and throttle position sensor (TPS) connector.
- Remove the alternator adjusting bolt and the accessory drive belt.
- Disconnect the engine coolant temperature (ECT) sensor connector.
- Disconnect the heater inlet hose from the cylinder head.
- Disconnect the surge tank coolant hose at the throttle body.
- Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake boaster vacuum hose at the intake manifold.
- Disconnect the throttle body cable from the throttle body and the intake manifold.
- Remove the fuel injector rail and fuel injectors as an assembly.
- Remove the alternator adjusting bracket bolt from the intake manifold and remove the alternator adjusting bracket.
- Remove the intake manifold support bracket bolts and the intake manifold support bracket.
- Remove the intake manifold retaining nuts/bolts in the sequence shown.
- Remove the intake manifold and gasket.
To install:
- Clean the sealing surfaces of the intake manifold and the cylinder head.
- Install the intake manifold with a new gasket. Tighten the retaining nuts/bolts in the sequence shown to 18 ft. lbs. (25 Nm).
- Install the intake manifold support bracket and tighten the bracket bolts to 18 ft. lbs. (25 Nm).
- Install the intake manifold support bracket lower bolt-to-engine block.
- Install the fuel rail and fuel injectors as an assembly.
- Connect the throttle cable to the intake manifold and the throttle body.
- Connect all of the necessary vacuum lines that were previously disconnected.
- Connect the heater inlet hose to the cylinder head.
- Connect the surge tank coolant hose to the throttle body.
- Install the alternator adjusting bracket at the intake manifold and tighten the bracket bolts to 11 ft. lbs. (15 Nm).
- Install the alternator adjusting bolt and the accessory drive belt.
- Connect the ECT sensor connector, IAC valve connector and TPS connector.
- Connect the air intake assembly to the throttle body.
- Connect the IAT sensor connector.
- Connect the powertrain control module (PCM)/engine control module (ECM) ground terminal to the intake manifold.
- Reinstall the fuel pump fuse.
- Connect the negative battery cable.
- Refill the cooling system to the correct level.
- Start the engine and check for leaks.
Pic 1: Intake manifold bolt removal sequence—1.6L engine
Pic 2: Intake manifold bolt tightening sequence—1.6L engine