Intake Manifold Replacement - Lower

Removal Procedure

Important: You do not have to remove the upper intake manifold in order to remove the lower intake manifold.





1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Remove the engine cover. Refer to Engine Cover Replacement.
3. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
5. Remove the air cleaner outlet duct from the throttle body assembly. Refer to Air Cleaner Outlet Duct Replacement.
6. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. Refer to Accelerator Controls Cable Replacement.
7. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement.
8. Disconnect the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.





9. Disconnect the following electrical connectors:
^ The Throttle Position (TP) sensor (1)
^ The Idle Air Control (IAC) motor (2)
^ The Engine Coolant Temperature (ECT) gauge sensor (3)
^ The A/C high pressure switch (4), if equipped





10. Disconnect the following electrical connectors:
^ The fuel meter body assembly connector (1)
^ The EVAP canister purge solenoid valve (2)
^ The Manifold Absolute Pressure (MAP) sensor (3)





11. Disconnect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The EGR valve (2)
^ The Engine Coolant Temperature (ECT) sensor (3)
12. Remove the ground wire (4) from the stud at the water outlet.





13. Remove the radiator inlet hose at the water outlet. Refer to Radiator Hose Replacement in Cooling System.
14. Remove the heater hose from the intake manifold. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
15. Remove the water pump inlet hose from the intake manifold.





16. Disconnect the A/C vacuum hose from the intake manifold.
17. Disconnect the power brake booster vacuum hose from the intake manifold.
18. Remove the power brake booster vacuum hose bracket and nut.





19. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
20. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
21. Remove the distributor. Refer to Distributor Replacement.
22. Disconnect the fuel supply and the return pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
23. Remove the Ignition Control Module (ICM). Refer to Ignition Coil and ICM Replacement.





24. Remove the spark plug wire harness retainer from the Exhaust Gas Recirculation (EGR) valve inlet pipe.
25. Remove the clamp bolt for the EGR valve inlet pipe.
26. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.





27. In order to remove the front intake manifold bolt, perform the following:
27.1. Remove the drive belt. Refer to Drive Belt Replacement.
27.2. Loosen the nut for the power steering pump rear bracket.
27.3. Remove the bolts and the nut for the power steering pump mounting bracket.
27.4. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
27.5. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
28. Remove the lower intake manifold. Refer to Intake Manifold Removal.
29. Clean all sealing surfaces and the intake manifold. Refer to Intake Manifold Clean and Inspect.
30. If the intake manifold requires replacement refer to Intake Manifold Disassemble and Intake Manifold Assemble.


Installation Procedure





1. Install the lower intake manifold. Refer to Intake Manifold Installation.
2. Reposition the power steering pump mounting bracket.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the power steering pump mounting bracket three bolts and the nut.
^ Tighten the power steering pump mounting bracket bolts and the nut and the power steering pump rear bracket nut to 41 Nm (30 ft. lbs.).
4. Install the drive belt. Refer to Drive Belt Replacement.
5. Install the Exhaust Gas Recirculation (EGR) valve inlet pipe to the intake and the exhaust manifolds. Refer to Exhaust Gas Recirculation (EGR) Pipe Replacement.
6. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
7. Install the fuel supply and return pipes to the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).





Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.

8. Remove the spark plug for number one cylinder.
9. Rotate the crankshaft until number one cylinder is in the compression stroke.
10. Align the two reference marks on the crankshaft balancer (1) and (4) with the two alignment marks (2) and (3) on the front cover.
11. Install the spark plug. Refer to Spark Plug Replacement.
12. Install the distributor. Refer to Distributor Replacement.
13. Install the ICM. Refer to Ignition Coil and ICM Replacement.





14. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body.
^ Tighten the accelerator control cable bracket nuts and studs to 12 Nm (106 inch lbs.).





15. Install the power brake booster vacuum hose bracket to the intake manifold stud.
^ Tighten the bracket nut to 11 Nm (97 inch lbs.).
16. Connect the power brake booster vacuum hose to the intake manifold.
17. Install the A/C vacuum hose to the intake manifold.





18. Install the water pump inlet hose to the intake manifold.
19. Install the heater hoses. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
20. Install the radiator inlet hose to the water outlet. Refer to Radiator Hose Replacement in Cooling System.





21. Connect the following electrical connectors:
^ The Throttle Position (TP) sensor (1)
^ The Idle Air Control (IAC) motor (2)
^ The Engine Coolant Temperature (ECT) gauge sensor (3)
^ The A/C high pressure switch (4), if equipped





22. Connect the following electrical connectors:
^ The fuel meter body assembly connector (1)
^ The EVAP canister purge solenoid valve (2)
^ The Manifold Absolute Pressure (MAP) sensor (3)





23. Connect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The EGR valve (2)
^ The Engine Coolant Temperature (ECT) sensor (3)
24. Install the ground wire (4) and the nut to the water outlet stud.
^ Tighten the ground wire nut to 10 Nm (88 inch lbs.).





25. Install the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
26. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement.
27. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to Accelerator Controls Cable Replacement.
28. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
29. Install air cleaner outlet duct to the throttle body. Refer to Air Cleaner Outlet Duct Replacement.
30. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
31. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
32. Install the engine cover. Refer to Engine Cover Replacement.