Intake Manifold: Service and Repair
Removal1. Release fuel system pressure as outlined under ``Fuel System Pressure Release.''
2. Disconnect battery ground cable and drain cooling system.
3. Remove fresh air duct from air filter housing and inlet hose from intercooler.
4. Remove radiator hose to cylinder head, Fig. 3
5. Remove Direct Ignition System (DIS) coils from intake manifold, Fig. 4.
6. Remove throttle and speed control cables.
7. Disconnect intercooler to throttle body outlet hose.
8. Disconnect vacuum hoses from throttle body and remove harness.
9. Disconnect automatic idle speed (AIS) motor and throttle position sensor connectors.
10. Remove PCV breather/separator box and vacuum harness, brake booster, vacuum vapor harness and fuel pressure regulator harness from intake manifold.
11. Disconnect fuel injector and charge temperature wiring connector.
12. Remove fuel supply and return hose quick connect at fuel tube assembly, Fig. 5. Wrap shop towels around hoses to catch any gasoline spillage.
13. Remove intake manifold bolts then the intake manifold.
Installation
14. Reverse procedure to install, noting the following:
a. Use new manifold gaskets.
b. Use anti-seize compound on all threads.
c. Tighten bolts and nuts to specifications, Fig. 3.
1. Disconnect battery ground cable.
2. Remove fresh air duct from air filter housing.
Fig. 3 Manifold Torque Specifications. 1989-90 Turbocharged Engine:
3. Remove radiator hose to cylinder head, Fig. 3
Fig. 4 Direct Ignition System (DIS) Coil Location.:
4. Remove Direct Ignition System (DIS) Coils from intake manifold, Fig. 4
5. Remove throttle and speed control cables.
6. Disconnect intercooler to throttle body outlet hose.
7. Disconnect vacuum hoses from throttle body and remove harness.
8. Disconnect automatic idle speed (AIS) motor and throttle position sensor connectors.
9. Remove PCV breather/separator box and vacuum harness, brake booster, vacuum vapor harness and fuel pressure regulator harness from intake manifold.
10. Disconnect fuel injector and charge temperature wiring connector.
Fig. 5 Fuel Supply & Return Hose Connections:
11. Remove fuel supply and return hose quick connect at fuel tube assembly, Fig. 5. Wrap shop towels around hoses to catch any gasoline spillage.
12. Remove front engine mount through bolt and rotate engine forward away from cowl.
13. Remove coolant and oil lines from turbocharger, then remove wastegate rod-to-gate retaining clip.
14. Remove turbo retaining nuts, then disconnect oxygen sensor electrical connector and vacuum lines.
15. Raise and support vehicle, then remove the right front wheel and tire assembly.
16. Remove turbo to block support bracket, then the driveshaft assembly Fig. 3.
17. Separate oil drain back tube from turbo housing and remove fitting.
18. Disconnect exhaust pipe from turbo, then the remaining turbo to manifold retaining nut.
19. Remove lower coolant line and inlet fitting, then remove turbocharger.
20. Remove eight intake manifold screws and washers, then the intake manifold.
21. Remove eight exhaust manifold retaining nuts, then the exhaust manifold.
22. Reverse procedure to install, noting the following:
a. Use new manifold gaskets.
b. Use anti-seize compound on all threads.
c. Torque bolts and nuts to proper specifications, Fig. 3.