Intake Manifold Replacement - Lower

Removal Procedure





1. Disconnect the battery negative cable. Refer to Battery Replacement in Starting and Charging.
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 in Powertrain Management.
5. Remove the air cleaner outlet duct from the throttle body assembly. Refer to Air Cleaner Outlet Duct Replacement in Powertrain Management.
6. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
7. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
8. Disconnect PCV valve hose assembly from the intake manifold and the valve rocker arm cover.





9. Remove the nut holding the A/C hose bracket to the intake manifold stud, if equipped.
10. Remove the nut holding the engine wiring harness bracket to the intake manifold stud.





11. Disconnect the following electrical connectors:
^ The A/C compressor clutch, if equipped (1)
^ The A/C high pressure cutoff switch, if equipped (5)
^ The throttle position (TP) sensor (2)
^ The idle air control (IAC) motor (3)
^ The fuel meter body assembly connector (4)





12. Disconnect the following electrical connectors:
^ The manifold absolute pressure (MAP) sensor(4)
^ The EVAP canister purge solenoid valve (1)





13. Disconnect the EGR valve electrical connector (1).
14. Remove the ground wire (2) from the stud at the water outlet.





15. Remove the nut and the engine wiring harness bracket from the stud at the EVAP canister purge solenoid valve.
16. Move and secure the engine wire harness out of the way.
17. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Powertrain Management.





18. Remove the radiator inlet hose at the water outlet. Refer to Radiator Hose Replacement in Cooling System.
19. Remove the heater hose from the intake manifold. Refer to Hot Water Bypass Valve Replacement (Standard) or Hot Water Bypass Valve Replacement (RPO C60) in Heating and Air Conditioning.
20. Remove the water pump inlet hose from the intake manifold.





21. Disconnect the vacuum hose from the intake manifold.





22. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket.





23. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
24. Remove the distributor. Refer to Distributor Replacement in Powertrain Management.
25. Disconnect the fuel supply and the return pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.
26. Remove the ignition control module (ICM). Refer to Ignition Coil and ICM Replacement (HVS) in Powertrain Management.
27. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake and the exhaust manifolds. Refer to EGR Pipe Replacement in Powertrain Management.





28. In order to remove the front intake manifold bolt, perform the following:
28.1. Remove the drive belt. Refer to Drive Belt Replacement
28.2. Remove the A/C compressor side brace.
28.3. Loosen the nut for the power steering pump rear bracket.
28.4. Remove the oil filler tube bracket bolt and the oil filler tube.
28.5. Remove the bolts and the nut for the power steering pump mounting bracket.
28.6. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
28.7. 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 Removal.
30. Clean all sealing surfaces and the intake manifold. Refer to Intake Manifold Clean and Inspect.
31. 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 A/C compressor side brace and bolts.
4.1. Tighten the A/C compressor side brace bolt to 50 Nm (37 ft. lbs.)
4.2. Tighten the side brace bolt to the generator bracket to 25 Nm (18 ft. lbs.).
5. Install the oil filler tube and bolt.
Tighten the oil filler tube bolt to 25 Nm (18 ft. lbs.).
6. Install the drive belt. Refer to Drive Belt Replacement.
7. Install the exhaust gas recirculation (EGR) valve inlet pipe to the intake and the exhaust manifolds. Refer to EGR Pipe Replacement in Powertrain Management.
8. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Powertrain Management.
9. Install the fuel supply and return pipes to the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.

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





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





16. 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.).





17. Install the vacuum hose to the intake manifold.





18. Install the transmission fluid fill tube and bolt to the accelerator control cable bracket.
Tighten the transmission fluid fill tube bolt 6 Nm (53 inch lbs.).





19. Install the water pump inlet hose to the intake manifold.
20. Install the heater hoses. Refer to Hot Water Bypass Valve Replacement (Standard) or Hot Water Bypass Valve Replacement (RPO C60) in Heating and Air Conditioning.
21. Install the radiator inlet hose to the water outlet. Refer to Radiator Hose Replacement in Cooling System.





22. Position the engine wiring harness.
23. Connect the following electrical connectors:
^ The A/C compressor clutch, if equipped (1)
^ The A/C high pressure cutoff switch, if equipped (5)
^ The throttle position (TP) sensor (2)
^ The idle air control (IAC) motor (3)
^ The fuel meter body assembly connector (4)





24. Connect the following electrical connectors:
^ The manifold absolute pressure (MAP) sensor(4)
^ The EVAP canister purge solenoid valve (1)





25. Connect the EGR valve electrical connector (1).
26. Install the ground wire (2) and the nut to the water outlet stud.
Tighten the ground wire nut to 19 Nm (14 ft. lbs.).





27. Install the nut and the engine wiring harness bracket to the stud for the EVAP canister purge solenoid valve.
Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.).





28. Install the nut and the engine wiring harness bracket to the intake manifold stud.
Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.).
29. Install the nut and the A/C hose bracket to the intake manifold stud, if equipped.
Tighten the A/C hose bracket nut to 5 Nm (44 inch lbs.).





30. Install the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
31. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
32. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
33. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
34. Install air cleaner outlet duct to the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Powertrain Management.
35. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
36. Connect the battery negative cable. Refer to Battery Replacement in Starting and Charging.
37. Install the engine cover. Refer to Engine Cover Replacement.