Intake Manifold Replacement (Lower)

REMOVAL PROCEDURE





1. Disconnect the battery negative cable.
2. Remove the air cleaner outlet duct from the throttle body.
3. Disconnect the hose fitting from the EVAP canister purge solenoid valve and move the hose aside.
4. 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 A/C compressor high pressure switch, if equipped
- The A/C low pressure cut out switch, if equipped.
- The A/C clutch switch, if equipped
- The Exhaust Gas Recirculation (EGR) valve
- The Engine Coolant Temperature (ECT) sensor
- The engine coolant temperature (ECT) gauge sensor
- The ignition coil
- The Ignition Control Module (ICM)

5. Remove the engine wiring harness from the engine wiring harness bracket at the right rear of the engine.





6. Remove the nut and the ground wire from the stud for the engine wiring harness bracket at the rear of the right cylinder head.





7. Remove the stud at the rear of the right cylinder head and the nut from the EVAP canister purge solenoid valve holding the engine wiring harness bracket.
8. Remove the engine wiring harness bracket.





9. Remove the engine wiring harness from the engine wiring harness bracket at the left rear of the engine.





10. Remove the bracket for the engine wiring harness from the upper intake manifold studs.





11. Remove the engine wiring harness nut and clip from the throttle body stud.
12. Remove the nut holding the ground wire to the water outlet.
13. Move the engine wiring harness aside.
14. Disconnect the accelerator control cable from the throttle shaft and the accelerator cable bracket.
15. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket.
16. Remove the EVAP canister purge solenoid valve.
17. Remove the distributor.





18. Drain the cooling system.
19. Remove the outlet heater hose from the intake manifold.
20. Remove the inlet heater hose from the water pump.
21. Remove the EGR valve.
22. Remove the water pump inlet hose form the intake manifold.





23. Remove the spark plug wire harness retainer from the EGR valve inlet pipe.
24. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake and exhaust manifold.
25. Disconnect the fuel supply and return pipes at the rear of the intake manifold.





26. Disconnect the vacuum brake booster hose.





27. Disconnect the PCV hose assembly from the intake manifold and the valve rocker arm cover.





IMPORTANT: Do not discharge the refrigerant.

28. Perform the following in order to remove the left front bolt for the intake manifold:
28.1. Remove the drive belt.
28.2. Loosen the nut for the power steering pump rear bracket at the side of the engine.
28.3. Remove the nut for the power steering pump rear bracket at the front of the engine.
28.4. Remove the bolts and the nut for the power steering pump mounting bracket.
28.5. Leave the A/C compressor, if equipped, and the power steering pump on the power steering pump mounting bracket.
28.6. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.





29. Remove the lower intake manifold. Refer to Intake Manifold Disassemble under Engine Unit Repair.
30. Clean all sealing surfaces. Refer to Intake Manifold Disassemble under Engine Unit Repair.

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. Refer to Intake Manifold Installation under Engine Unit Repair.





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 nut, and the power steering pump rear bracket nuts to 41 Nm (30 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

5. Install the drive belt.





6. Install the vacuum brake booster hose to the intake manifold.





7. Install the PCV hose assembly to the intake manifold and the valve rocker arm cover.
8. Install the fuel supply and return pipes to the rear of the intake manifold.





9. Install the exhaust gas recirculation (EGR) valve inlet pipe to the intake manifold and the exhaust manifold.
9.1. Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
9.2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
9.3. Tighten the EGR valve inlet pipe clamp bolt to 25 Nm (18 ft. lbs.).
10. Install the spark plug wire harness retainer on the EGR valve inlet pipe.





11. Remove the spark plug for number one cylinder.

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

12. Rotate the crankshaft until number one cylinder is in the compression stroke.
13. Align the two reference marks on the crankshaft balancer (1) and (4) with the two alignment marks (2) and (3) on the front cover.
14. Install the spark plug.
15. Install the distributor.





16. Install the water pump inlet hose to the intake manifold.
17. Install the EGR valve.
18. Install the outlet heater hose to the intake manifold. 19. Install the inlet heater hose to the water pump.
20. Fill the cooling system.





21. Install the accelerator control cable to the bracket and the throttle shaft.
22. Install the cruise control cable, if equipped to the bracket and the throttle shaft.
23. Install the left side bracket for the engine wiring harness on the lower intake manifold studs.
24. Install the engine wiring harness bracket nuts.
Tighten the engine wiring harness bracket nuts to 12 Nm (106 inch lbs.).





25. Install the engine wiring harness to the engine wiring harness bracket at the left rear of the engine.





26. Install the right side engine wiring harness bracket on the EVAP canister purge solenoid valve stud.
27. Install the stud and the nut for the engine wiring harness bracket.
- Tighten the engine wiring harness bracket nut to 10 Nm (88 inch lbs.).
- Tighten the engine wiring harness bracket stud to 25 Nm (18 ft. lbs.).





28. Install the ground wire and nut to the engine wiring harness bracket stud at the rear of the right cylinder head.
Tighten the ground wire nut to 8 Nm (71 inch lbs.).





29. Install the engine wiring harness to the engine wiring harness bracket at the right rear of the engine.
30. 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 A/C compressor high pressure switch, if equipped
- The A/C low pressure cut out switch, if equipped.
- The A/C clutch switch, if equipped
- The exhaust gas recirculation (EGR) valve
- The engine coolant temperature (ECT) sensor
- The engine coolant temperature (ECT) gauge sensor
- The ignition coil
- The Ignition Control Module (ICM)





31. Install the engine wiring harness clip and nut to the throttle body stud.
Tighten the engine wiring harness clip nut to 10 Nm (88 inch lbs.).
32. Install the ground wire and nut on the stud for the water outlet.
Tighten the ground wire nut to 8 Nm (71 inch lbs.).
33. Connect the hose fitting for the EVAP canister purge solenoid valve.
34. Install the air cleaner outlet duct to the throttle body.
35. Connect the battery negative cable.