Intake Manifold Replacement - Lower
Removal ProcedureImportant: You do not have to remove the upper intake manifold in order to remove the lower intake manifold.
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Disconnect the PCV hose from the air cleaner outlet duct.
4. Remove the air cleaner outlet duct from the throttle body and the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement.
5. Remove the accelerator control cable from the throttle shaft and the accelerator control cable bracket at the side of the throttle body. Refer to Accelerator Controls Cable Replacement.
6. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket at the side of the throttle body. Refer to Cruise Control Cable Replacement.
7. Remove the engine wiring harness and clip from the accelerator control cable bracket.
8. Remove the accelerator control cable bracket with the accelerator control cable and the cruise control cable from the throttle body.
9. Move and secure the accelerator control cable bracket with the cables out of the way.
10. Disconnect the secondary air injection (AIR) crossover pipe from the AIR pipe assemblies, if equipped.
11. Remove the AIR crossover pipe.
12. Disconnect the following electrical connectors:
^ The EVAP canister purge solenoid valve (1)
^ The Manifold Absolute Pressure (MAP) sensor (2)
^ The Ignition Control Module (ICY) (4)
^ The ignition coil (3)
13. Disconnect the following electrical connectors:
^ The A/C pressure switch (4), if equipped
^ The A/C compressor clutch (1), if equipped
^ The exhaust gas recirculation (EGR) valve (2)
^ The generator battery positive cable (3)
14. Disconnect the following electrical connectors:
^ The fuel meter body assembly (3)
^ The Throttle Position (TP) sensor (1)
^ The idle air control (IAC) motor (2)
^ The Engine Coolant Temperature (ECT) sensor (4)
15. Remove the nut holding the engine wiring harness bracket to the EVAP purge solenoid valve stud.
16. Remove the nut holding the ground wire to the engine wiring harness bracket stud at the rear of the right cylinder head.
17. Remove the stud holding the engine wiring harness bracket.
18. Remove the two nuts holding the engine wiring harness bracket to the upper intake manifold studs.
19. Remove the engine wiring harness bracket from the studs.
20. Move the engine wiring harness with the brackets aside.
21. Remove the radiator inlet hose at the water outlet. Refer to Radiator Hose Replacement - Inlet in Cooling System.
22. Remove the water pump inlet hose from the intake manifold.
23. Remove the heater hoses from the engine. Refer to Heater Hoses Replacement.
24. Remove the distributor. Refer to Distributor Replacement.
25. Disconnect the fuel supply and return pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
26. Disconnect PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
27. Disconnect the power brake booster vacuum hose from the intake manifold.
28. Disconnect the hose to the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
29. Remove the spark plug wire harness retainer from the exhaust gas recirculation (EGR) valve inlet pipe.
30. Remove the clamp bolt for the EGR valve inlet pipe.
31. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
32. In order to remove the front intake manifold bolt, perform the following:
32.1. Remove the drive belt. Refer to Drive Belt Replacement.
32.2. Loosen the power steering pump rear bracket side nut.
32.3. Remove the power steering pump rear bracket front nut.
32.4. Remove the bolts and the nut for the power steering pump mounting bracket.
32.5. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
32.6. Slide the power steering pump mounting bracket forward to access the bolt at the front of the intake manifold.
33. Remove the lower intake manifold. Refer to Intake Manifold Removal.
Important: Do not immerse the assembled intake manifold in cleaning solvent.
34. Clean all sealing surfaces and the intake manifold. Refer to Intake Manifold Clean and Inspect.
35. 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. Position the power steering pump mounting bracket.
3. Install the three bolts and the nut.
Notice: Refer to Fastener Notice in Service Precautions.
4. Install the front nut for the power steering pump rear bracket.
Tighten the power steering pump mounting bracket bolts, the nut, and the power steering pump rear bracket nuts to 41 Nm (30 ft. lbs.).
5. Install the drive belt. Refer to Drive Belt Replacement.
6. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold. 6.1. Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
6.2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
6.3. Tighten the EGR valve inlet pipe clamp bolt 25 Nm (18 ft. lbs.).
7. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
8. Install the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
9. Install the power brake booster vacuum hose to the intake manifold.
10. Install the EVAP canister purge solenoid valve hose. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
11. Install the fuel supply and return pipes to the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.
12. Remove the spark plug for number one cylinder.
13. Rotate the crankshaft until number one cylinder is in the compression stroke.
14. Align the two reference marks on the crankshaft balancer (1) and (4) with the two alignment marks (2) and (3) on the front cover.
15. Install the spark plug. Refer to Spark Plug Replacement.
16. Install the distributor. Refer to Distributor Replacement.
17. Install the water pump inlet hose to the intake manifold.
18. Install the heater hoses to the engine. Refer to Heater Hoses Replacement.
19. Install the radiator inlet hose to the water outlet. Refer to Radiator Hose Replacement - Inlet in Cooling System.
20. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
21. Position the engine wiring harness and the engine wiring harness brackets.
22. Install the stud at the rear of the right cylinder head for the engine wiring harness bracket.
Tighten the engine wiring harness bracket stud to 25 Nm (18 ft. lbs.).
23. Install the nut holding the engine wiring harness bracket to the EVAP purge canister solenoid stud.
Tighten the engine wiring harness bracket nut to 9 Nm (80 inch lbs.).
24. Install the nut and the ground wire to engine wiring harness bracket stud at the rear of the right cylinder head.
Tighten the ground wire nut to 16 Nm (12 ft. lbs.).
25. Install the nuts and the engine wiring harness bracket to the upper intake manifold studs.
Tighten the engine wiring harness bracket nuts 12 Nm (106 inch lbs.).
26. Connect the following electrical connectors:
^ The EVAP canister purge solenoid valve (1)
^ The manifold absolute pressure (MAP) sensor (2)
^ The ignition control module (ICM) (4)
^ The ignition coil (3)
27. Connect the following electrical connectors:
^ The A/C pressure switch (4), if equipped
^ The A/C compressor clutch (1), if equipped
^ The exhaust gas recirculation (EGR) valve (2)
^ The generator battery positive cable (3)
28. Connect the following electrical connectors:
^ The fuel meter body assembly (3)
^ The throttle position (TP) sensor (1)
^ The idle air control (IAC) motor (2)
^ The engine coolant temperature (ECT) sensor (4)
29. Connect the AIR crossover pipe to the AIR pipe assemblies.
30. Install the accelerator control cable bracket with the accelerator control cable and the cruise control cable and the nuts to the throttle body.
Tighten the nuts to 9 Nm (80 inch lbs.).
31. Install the accelerator cable to the throttle shaft the accelerator control cable bracket. Refer to Accelerator Controls Cable Replacement.
32. Install the cruise control cable, if equipped to the throttle shaft the accelerator control cable bracket. Refer to Cruise Control Cable Replacement.
33. Install the engine wiring harness and clip to the accelerator control cable bracket.
34. Install the air cleaner outlet duct to the throttle body and the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement.
35. Connect the PCV hose to the air cleaner outlet duct.
36. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.