Lower
Intake Manifold Replacement (Lower)Removal Procedure
1. Disconnect the battery negative cable.
2. Remove the air cleaner outlet duct from the throttle body.
3. Remove the air cleaner assembly.
4. Drain the cooling system.
5. Remove the radiator inlet hose at the water outlet.
6. Remove the heater hose from the intake manifold.
7. Remove the water pump inlet hose form the intake manifold.
8. Disconnect the accelerator control cable from the throttle shaft and the accelerator cable bracket.
9. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket.
10. Remove the accelerator cable bracket from the throttle body and the intake manifold.
11. Remove the accelerator and the cruise control cable bracket from the throttle bracket. Leave the accelerator and cruise control cables and the wiring harness on the bracket.
12.Remove 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 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
- The ignition coil
- The ignition control module (1CM)
13. Remove the engine wiring harness from the retainers.
14. Move the engine wiring harness aside.
16. Remove the distributor.
16. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake and exhaust manifold.
17. Disconnect the fuel supply and return pipes at the rear of the intake manifold.
18. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.
19. Disconnect the vacuum brake booster hose
20. Disconnect the PCV hose assembly from the intake manifold and the valve rocker arm cover.
21. Remove the EVAP canister purge solenoid valve.
Important: Do not discharge the refrigerant.
22. Perform the following in order to remove the left front bolt for the intake manifold:
1. Remove the drive belt.
2. Loosen the nut for the power steering pump rear bracket at the side of the engine.
3. Remove the secondary air injection (AIR) reactor pipe bracket nut from the power steering pump rear bracket front stud, if equipped.
4. Remove the nut for the power steering pump rear bracket at the front of the engine.
5. Remove the bolts and the nut for the power steering pump mounting bracket.
6. Leave the A/C compressor, if equipped, and the power steering pump on the power steering pump mounting bracket.
7. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
23. Remove the lower intake manifold.
24. 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. Position the power steering pump mounting bracket.
3. Loosely install the power steering pump mounting bracket bolts and nuts.
4. Install the nut for the power steering pump rear bracket at the front of the engine.
Tighten the power steering pump mounting bracket bolts and the power steering pump rear bracket nuts to 41 N.m (30 lb ft).
5. Install the AIR reactor pipe bracket nut to the power steering pump rear bracket front stud, if equipped.
Tighten the AIR reactor pipe bracket nut to 41 N.m (30 lb ft).
6. Install the drive belt.
7. Install the EVAP canister purge solenoid valve.
8. Connect the vacuum brake booster hose.
9. Connect the vacuum hose to the intake manifold, if equipped with A/C.
10. Install the PCV hose assembly to the intake manifold and the valve rocker arm cover.
11. Install the fuel supply and return pipes to the rear of the intake manifold.
12. Install the exhaust gas recirculation (EGR) valve inlet pipe to the intake manifold and the exhaust manifold.
1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N.m (18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N.m (22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N.m (18 lb ft).
Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.
13. Remove the spark plug for number one cylinder.
14. Rotate the crankshaft until number one cylinder is in the compression stroke.
15. Align the two reference marks on the crankshaft balancer (1) and (4) with the two alignment marks (2) and (3) on the front cover.
16. Install the spark plug.
17. Install the distributor.
18. Position the engine wiring harness.
19. Install the engine wiring harness in the retainers.
20. Install 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 A/C compressor high pressure switch, if equipped.
- The A/C compressor clutch switch, if equipped.
- The exhaust gas recirculation (EGR) valve
- The engine coolant temperature (ECT) sensor
- The ignition coil
- The ignition control module (ICM)
21. Install the accelerator cable and cruise control bracket to the throttle body.
Tighten the accelerator cable and cruise control bracket nuts to 9 N.m (80 lb in).
22. Install the accelerator cable bracket to the intake manifold and the throttle body.
Tighten the accelerator cable bracket studs and nuts to 12 N.m (106 lb in).
23. Install the accelerator control cable to the bracket and the throttle shaft.
24. Install the cruise control cable, if equipped to the bracket and the throttle shaft.
25. Install the water pump inlet hose to the intake manifold.
26. Install the heater hose to the intake manifold.
27. Install the radiator inlet hose to the water outlet.
28. Fill the cooling system.
29. Install the air cleaner assembly.
30. Install the air cleaner outlet duct to the throttle body.
31. Connect the battery negative cable.