Intake Manifold Replacement - Lower

Intake Manifold Replacement- Lower

Removal Procedure





1. Disconnect the battery negative cable.
2. Drain the engine coolant. Refer to: Service and Repair
3. Remove the air cleaner intake duct. Refer to: Service and Repair
4. Remove the engine cover. Refer to: Service and Repair
5. Remove the coolant reservoir. Refer to: Service and Repair
6. Remove the following coolant hoses:
6.1. Upper radiator hose. Refer to: Service and Repair
6.2. Inlet heater hose. Refer to: Service and Repair
6.3. Outlet heater hose. Refer to: Service and Repair
6.4. Coolant by-pass hose. Refer to: Service and Repair
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. Refer to: Service and Repair
11. Remove the fuel pipes from the rear of the engine. Refer to: Service and Repair
12. Remove the accelerator control cable and the cruise control cables, if equipped, from the throttle shaft. Refer to: Service and Repair
13. Remove the accelerator control cable bracket from the throttle body and the lower intake manifold.
14. Remove the ignition Coil Service and Repair and ICM bracket Service and Repair.
15. Remove the EGR pipe from the intake manifold. Refer to: Service and Repair





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

16. Remove the Air Conditioning (A/C) compressor, if equipped, and set aside. Refer to: Service and Repair
17. Remove the power steering pulley from the power steering pump. Refer to: Service and Repair
18. Remove the power steering pump mounting bracket.
19. Remove the left side valve rocker arm cover. Refer to: Service and Repair
20. Remove the right side valve rocker arm cover. Refer to: Service and Repair
21. Remove the lower intake manifold from the engine. Refer to: Overhaul





22. Clean all sealing surfaces.

Installation Procedure





1. Install the lower intake manifold to the engine. Refer to: Overhaul
2. Install the left side valve rocker arm cover. Refer to: Service and Repair
3. Install the right side valve rocker arm cover. Refer to: Service and Repair
4. Install the power steering pump mounting bracket.
5. Install the Air Conditioning (A/C) compressor, if equipped. Refer to: Service and Repair





6. Connect the Exhaust Gas Recirculation (EGR) pipe to the bracket and the front of the intake manifold. Refer to: Service and Repair
7. Install the ignition Coil Service and Repair and the ICM bracket Service and Repair.
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. Refer to: Service and Repair
11. Install the fuel pipes to the rear of the engine. Refer to: Service and Repair
12. Install the distributor to the engine. Refer to: Service and Repair
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. Refer to: Service and Repair
19. Install the inlet heater hose. Refer to: Service and Repair
20. Install the outlet heater hose. Refer to: Service and Repair
21. Install the coolant bypass hose. Refer to: Service and Repair
22. Install the coolant reservoir. Refer to: Service and Repair
23. Install the engine cover. Refer to: Service and Repair
24. Install the air cleaner assembly. Refer to: Service and Repair
25. Fill the engine with coolant. Refer to: Service and Repair
26. Connect the battery negative cable.