Intake Manifold Replacement - Lower

Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Cable Replacement (Battery Disconnect/Connect) in Starting and Charging.
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:
7. Remove the following coolant hoses:
8. Upper radiator hose.
9. Inlet heater hose.
10. Outlet heater hose.
11. Coolant by-pass hose
12. Disconnect the following electrical connectors.
13. SCPI injector electrical connector.
14. Manifold absolute pressure (MAP) sensor
15. Canister purge solenoid
16. Idle air control (IAC) motor
17. Throttle position (TP) sensor
18. Exhaust gas recirculation (EGR) valve
19. Engine coolant temperature (ECT) sensor
20. Remove AIR Bypass hose assembly, if so equipped.
21. Use a twisting motion in order to remove the brake booster vacuum hose, if equipped.
22. Remove the distributor from the engine.
23. Remove the fuel pipes from the rear of the engine.
24. Remove the accelerator control cable and the cruise control cables, if equipped, from the throttle shaft.
25. Remove the accelerator control cable bracket from the throttle body.
26. Remove the ignition coil and ICM bracket.
27. Remove the EGR inlet pipe from the intake manifold.

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





28. Remove the Air Conditioning (A/C) compressor, it equipped, and set it aside.
29. Remove the power steering pulley from the power steering pump.
30. Remove the power steering pump mounting bracket.
31. Remove the left side valve rocker arm cover.
32. Remove the right side valve rocker arm cover.





33. Remove the lower intake manifold from the engine.
34. Clean all sealing surfaces.

Installation Procedure





1. Install the lower intake manifold to the engine.
2. Remove the left side valve rocker arm cover.
3. Remove the right side valve rocker arm cover.
4. Remove the power steering pump mounting bracket.
5. Install the air conditioning (A/C) compressor, if equipped.





6. Connect the Exhaust Gas Recirculation (EGR) pipe to the bracket and the front of the intake manifold.
7. Install the ignition coil and the ICM bracket.
8. Install AIR Bypass hose assembly, if so equipped.





9. Install the accelerator control cable bracket to the throttle body.
10. Install the accelerator control cable and the cruise control cable, if 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.