Intake Manifold Replacement - Lower

Intake Manifold Replacement - Lower
Removal Procedure





1. Disconnect the battery negative cable.
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:
6.1. Upper radiator hose.
6.2. Inlet heater hose.
6.3. Outlet heater hose.
6.4. Coolant by-pass hose.
7. Disconnect the following electrical connectors.
- SCPI injector electrical connector.
- Manifold Absolute Pressure (MAP) sensor.
- EVAP canister purge solenoid valve.
- Idle Air Control (IAC) motor.
- Throttle Position (TP) sensor.
- Exhaust Gas Recirculation (EGR) valve.
- Engine Coolant Temperature (ECT) sensor.
8. Remove AIR bypass hose assembly, if so equipped.
9. Use a twisting motion in order to remove the brake booster vacuum hose, if equipped.
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 and the lower intake manifold.
14. Remove the ignition coil and ECM bracket.
15. Remove the EGR pipe from the intake manifold.





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

16. Remove the Air Conditioning (A/C) compressor, if equipped, and set aside.
17. Remove the power steering pulley from the power steering pump.
18. Remove the power steering pump mounting bracket.
19. Remove the left side valve rocker arm cover.
20. Remove the right side valve rocker arm cover.





21. Remove the lower intake manifold from the engine.
22. Clean all sealing surfaces.

Installation Procedure





1. install the lower intake manifold to the engine. Refer to "Lower Intake Manifold Installation".
2. Install the left side valve rocker arm cover.
3. Install the right side valve rocker arm cover.
4. Install 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 ECM bracket.
8. Install AIR bypass hose assembly, if so equipped.





9. Install the accelerator control cable bracket to the throttle body and the lower intake manifold.
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 tube 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.
- EVAP canister purge solenoid valve.
- Idle Air Control (IAC) motor.
- Throttle Position (TP) sensor.
- Exhaust Gas Recirculation (EGR) valve.
- Engine Coolant Temperature (ECT) sensor.
16. Install the AIR bypass hose assembly, if so equipped.
17. Install the brake booster vacuum hose, if so equipped.
18. Install the upper radiator hose.
19. Install the inlet heater hose.
20. Install the outlet heater hose.
21. Install the coolant bypass hose.
22. Install the coolant reservoir.
23. Install the engine cover.
24. Install the air cleaner assembly.
25. Fill the engine with coolant.
26. Connect the battery negative cable.