Intake Manifold Replacement (Lower)

REMOVAL PROCEDURE





1. Disconnect the battery negative cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Drain the engine coolant.
3. Remove the air cleaner intake duct.
4. Remove the engine cover.
5. Remove the coolant reservoir.
6. Remove the following coolant hoses:
- Upper radiator hose
- Both heater hoses
- Coolant by-pass hose

7. Disconnect the following electrical connectors.
- SCPI injector electrical connector.
- Manifold Absolute Pressure (MAP) sensor
- Canister purge solenoid
- Idle Air Control (IAC) motor
- Throttle Position (TP) sensor
- Exhaust Gas Recirculation (EGR) valve
- Engine Coolant Temperature (ECT) sensor

8. Use a twisting motion in order to remove the brake booster vacuum hose, if equipped.
9. Remove the PCV at the intake manifold (twist to unlock).
10. Remove the distributor from the engine.
11. Remove the fuel pipes from the rear of the engine.
12. Remove the accelerator control cable and the cruise control cables, if equipped, from the throttle shaft.
13. Remove the accelerator control cable bracket from the throttle body.
14. Remove the ignition coil and ICM bracket.





15. Remove the EGR inlet pipe from the intake manifold.
16. Remove the air conditioning (A/C) compressor, if equipped, and set it aside.

IMPORTANT: It is not necessary to discharge the A/C refrigerant.

17. Remove the power steering pulley from the power steering pump.





18. Remove the power steering pump mounting bracket using the following procedure:
- Remove two nuts from the back of the power steering pump.
- Remove the nut from the stud.
- Remove the three bolts from the mounting bracket.
- Slide the power steering pump mounting bracket forward, with the power steering pump still attached.
- Lay the pump and the bracket aside.

19. Remove one valve rocker arm cover.
20. Remove the lower intake manifold from the engine. Refer to Intake Manifold Removal under Engine Unit Repair.
21. Clean all sealing surfaces. Refer to Intake Manifold Clean and Inspect under Engine Unit Repair.

INSTALLATION PROCEDURE





1. Install the lower intake manifold to the engine.
Refer to Intake Manifold Replacement (Upper).
Refer to Intake Manifold Installation under Engine Unit Repair.
2. Install the valve rocker arm cover.
3. Install the power steering pump mounting bracket using the following procedure:
- Install the power steering pump bracket onto the stud.
- Install the nut onto the stud finger tight.
- Install the three bolts finger tight.
- Install the two nuts to the back of the power steering pump finger tight.
- Tighten the nuts and the bolts to 44 Nm (32 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.





4. Install the power steering pump pulley to the power steering pump.
5. Connect the electrical connector to the power steering pump.
6. Install the air conditioning (A/C) compressor, if equipped.





7. Connect the Exhaust Gas Recirculation (EGR) pipe to the bracket and the front of the intake manifold.
8. Install the ignition coil and the ICM bracket.
9. Install the accelerator control cable bracket to the throttle body.
10. Install the accelerator control cable and the cruise control cable, it equipped, to the throttle shaft.
11. Install the fuel pipes to the rear of the engine.
12. Install the distributor to the engine.
13. Install the PCV at intake manifold using a twisting motion in order to lock.
14. Install the vacuum brake booster hose, if equipped.
15. Connect the following electrical connectors.
- SCPI injector electrical connector.
- Manifold Absolute Pressure (MAP) sensor
- Canister purge solenoid
- Idle Air Control (IAC) motor
- Throttle Position (TP) sensor
- Exhaust Gas Recirculation (EGR) valve
- Engine Coolant Temperature (ECT) sensor

16. Install the coolant reservoir.
17. Install the engine cover..
18. Install the air cleaner assembly.
19. Fill the engine with coolant.
20. Connect the battery negative cable.