Lower Intake Manifold Replacement
INTAKE MANIFOLD AND SEALSREMOVE OR DISCONNECT
1. Negative battery cable.
2. Air intake duct.
3. Partially drain cooling system.
4. Throttle body coolant hoses. Wrap a shop towel around hoses when disconnecting to avoid spillage.
5. Electrical connectors for Throttle Position (TP) sensor, Idle Speed Control (ISC) motor, and cruise control servo.
6. Vacuum hoses at brake vacuum booster, throttle body and cruise control servo.
7. PCV hose at intake manifold.
8. Accelerator cable at throttle body, cruise control bracket and ISC actuator bracket and position out of the way.
9. Transaxle vent hose, cruise control servo, and EVAP solenoid vacuum hoses at cruise control bracket.
10. Injector harness main connector and harness at ISC actuator bracket and cruise control bracket.
11. Cruise control servo and bracket.
12. Relieve fuel system pressure.
13. Fuel pipe quick connects at fuel pipe bundle in engine compartment.
14. Spark plugs wires at front bank and lay aside.
15. Transaxle range control cable at ISC actuator bracket.
Intake Manifold And Throttle Body Service:
16. Four intake manifold bolts and lift intake manifold with throttle body out of engine compartment.
Intake Manifold Seals:
12. Intake manifold seals and spacers at cylinder heads (if replacement is necessary).
DISASSEMBLE
1. Intake manifold top cover.
2. Fuel pipe retainer at ISC actuator bracket.
3. Four throttle body bolts and throttle body with ISC actuator and bracket.
4. Fuel rail assembly.
5. Fuel feed and return pipes.
6. Brake booster vacuum pipe.
ASSEMBLE
1. Brake booster vacuum pipe.
2. Fuel feed and return pipes
3. Fuel rail assembly.
4. Intake manifold top cover.
TIGHTEN
^ Torque bolts to 11.5 Nm (102 lb. in.).
5. Position new throttle body O-ring seal on throttle body with petroleum jelly.
IMPORTANT
^ Do not reuse old throttle body 0 - ring seal. The seal swells when exposed to fuel and oil and will not seat properly to the throttle body and intake manifold once the throttle body has been removed.
^ Do not use silicone lubricants on the throttle body 0-ring seal. Silicone lubricants may damage the 0-ring seal.
6. Throttle body with four bolts to intake manifold.
TIGHTEN
^ Torque bolts to 12 Nm (106 lb. in.).
INSTALL OR CONNECT
1. Intake manifold seals and spacers at cylinder heads (if replacement is necessary).
2. Intake manifold seals and spacers at cylinder heads (if replacement was necessary).
TIGHTEN
^ Torque bolts to 6 Nm (53 lb. in.) then an additional 120° (1/3 turn).
3. Transaxle range control cable at ISC actuator bracket.
4. Fuel pipe quick connects at engine compartment fuel pipes.
5. Cruise control servo and bracket.
6. Injector harness main connector and harness at ISC actuator bracket and cruise control bracket.
7. Transaxle vent hose, cruise control servo, and EVAP solenoid vacuum hoses at cruise control bracket.
8. Accelerator cable at throttle body, cruise control bracket and ISC actuator bracket.
7. PCV hose at intake manifold pipe.
10. Vacuum hoses at brake vacuum booster, throttle body and cruise control servo.
11. TP sensor, ISC actuator and cruise control servo electrical connectors.
12. Spark plugs wires at front bank.
13. Throttle body coolant hoses.
14. Air intake duct.
15. Tighten fuel filler cap.
16. Negative battery cable.
17. Fill cooling system to proper level.