Intake Manifold: Service and Repair

Lower Intake Manifold

Removal and Installation
1. Drain the supercharger coolant.
2. Release the fuel system pressure.





3. Disconnect the supercharger degas hose.
4. Remove the supercharger belt.





5. Disconnect the coolant hose.
6. Remove the air cleaner outlet tube.





7. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors.





8. Disconnect the vacuum hose.
9. Disconnect the fuel hose spring lock coupling.





10. Disconnect the accelerator controls.
^ Disconnect the accelerator cable.
^ If equipped, disconnect the speed control cable.





11. Remove the accelerator cable bracket bolts.





12. Remove the throttle body and spacer assembly.





13. Release the clip and position the accelerator cable bracket and the cables aside.





14. Disconnect the electrical connectors from the fuel pulse damper, exhaust gas recirculation (EGR) vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.





15. Disconnect the vacuum hoses from the differential pressure feedback EGR system.





16. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid and the actuator.





17. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.





18. Disconnect the vacuum hose from the EGR valve.





19. Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside.





20. Remove the vacuum accessory bracket mounting nut.





21. Remove the mounting bolts and the vacuum accessory bracket.





22. Disconnect the exhaust manifold to EGR valve tube.





23. Disconnect the barometric pressure (BARD) sensor electrical connector.





24. Disconnect the positive crankcase ventilation hose.





25. Separate the fuel charging wiring harness from the fuel injection supply manifold in four places and position the harness aside.





26. Remove the ten bolts and the intake manifold, and the supercharger and fuel supply manifold as an assembly.





27. NOTE: Inspect the intake manifold gaskets and install new gaskets, if necessary.

To install, reverse the removal procedure.
^ Tighten the intake manifold bolts in the sequence shown.
28. Fill and bleed the supercharger cooling system.