Intake Manifold Replacement - Lower
Removal Procedure1. Disconnect the battery negative cable. Refer to Battery Cable Replacement (Battery Disconnect/Connect) in Starting and Charging.
2. Remove the engine cover.
3. Drain the cooling system.
4. Remove the upper fan shroud section.
5. Disconnect the PCV tube.
6. Remove the air inlet duct from the throttle body assembly.
7. Remove the radiator inlet hose at the water outlet.
8. Remove the generator. Refer to Generator Replacement (Gasoline Engines) in Starting and Charging.
9. Remove the heater hose from the intake manifold.
10. Remove the water inlet hose from the intake manifold.
11. Remove the ground wire from the stud for the water outlet.
12. Remove the accelerator control cable from the throttle shaft. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
13. Disconnect the cruise control cable, if equipped.
14. Remove the accelerator and cruise control cables bracket from the throttle body and the intake manifold.
15. Disconnect the following electrical connectors:
^ The fuel meter body assembly
^ The EVAP canister purge solenoid valve.
^ The idle air control (IAC) motor
^ The throttle position (TP) sensor
^ The manifold absolute pressure (MAP) sensor
^ The A/C compressor high pressure switch, if equipped
^ The A/C clutch switch, if equipped
^ The exhaust gas recirculation (EGR) valve
^ The engine coolant temperature (ECT) sensor
16. In order to remove the front lower intake manifold bolt, perform the following:
16.1. Remove the drive belt.
16.2. Loosen the power steering pump rear bracket side nut.
16.3. Remove he power steering pump rear bracket front nut.
16.4. Remove the bolts and the nut for the power steering pump mounting bracket.
16.5. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
16.6. Slide the power steering pump mounting bracket forward to access the bolt at the front of the intake manifold.
17. Remove the distributor.
18. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake manifold and the exhaust manifold.
19. Disconnect the fuel supply and return pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.
20. Disconnect PCV valve hose from the intake manifold and the valve rocker arm cover.
21. Disconnect the A/C vacuum hose from the intake manifold, if equipped with A/C.
22. Disconnect the vacuum brake booster hose from the intake manifold.
23. Remove the vacuum brake booster hose bracket.
24. Remove bolts holding the Ignition Control Module (ICM) and set the ICM aside.
25. Disconnect the EVAP canister purge solenoid valve hose.
26. Remove the lower intake manifold bolts.
27. Remove the lower intake manifold.
28. Clean all sealing surfaces.
Installation Procedure
Notice: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.
1. Install the lower intake manifold.
2. Connect the EVAP canister purge solenoid valve pipe.
3. Install the ICM.
4. Install the fuel supply and return pipes to the rear of the intake manifold.
5. Install the PCV valve hose to valve rocker arm cover and the valve rocker arm cover.
6. Connect the A/C vacuum hose to the intake manifold, if equipped with A/C.
7. Connect the vacuum brake booster hose to the intake manifold.
Notice: Refer to Fastener Notice in Service Precautions.
8. Install the vacuum brake booster hose bracket and nut to the intake manifold stud.
^ Tighten the bracket nut to 11 Nm (97 inch lbs.).
9. Install the Exhaust Gas Recirculation (EGR) valve inlet pipe to the intake manifold and the exhaust manifold.
^ Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
^ Tighten the EGR valve inlet pipe clamp bolt to 25 Nm (18 ft. lbs.).
^ Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.
10. Remove the spark plug for number one cylinder.
11. Rotate the crankshaft until number one cylinder is in the compression stroke.
12. Align the two reference marks on the crankshaft balancer (1) and (4) with the two alignment marks (2) and (3) on the front cover.
13. Install the spark plug.
14. Install the distributor.
15. Reposition the power steering pump mounting bracket.
16. Install the three bolts and the nut for the power steering pump mounting bracket.
17. Install the front nut for the power steering pump rear bracket
^ Tighten the power steering pump mounting bracket bolts, the nut, and the power steering pump rear bracket nuts to 41 Nm (30 ft. lbs.).
18. Install the drive belt.
19. Install the ground wire to the water outlet stud.
^ Tighten the nut to 10 Nm (88 inch lbs.).
20. Connect the following electrical connectors:
^ The fuel meter body assembly
^ The EVAP canister purge solenoid valve
^ The idle air control (IAC) motor
^ The throttle position (TP) sensor
^ The manifold absolute pressure (MAP) sensor
^ The A/C compressor high pressure switch
^ The A/C clutch switch
^ The exhaust gas recirculation (EGR) valve
^ The engine coolant temperature (ECT) sensor
21. Install the accelerator control cable bracket, bolts, and nuts to the intake manifold and the throttle body
^ Tighten the nuts and bolts to 12 Nm (106 inch lbs.).
22. Install the accelerator control cable to the throttle shaft.
23. Install the cruise control cable, if equipped.
24. Install the water inlet hose to the intake manifold.
25. Install the heater hoses.
26. Install the generator.
27. Install the radiator inlet hose to the water outlet.
28. Refill the cooling system.
29. Install air inlet duct to the throttle body.
30. Connect the PCV tube.
31. Install the upper fan shroud section.
32. Connect the battery negative cable.
33. Install the engine cover.