Intake Manifold Replacement - Lower

Removal Procedure





1. Disconnect the battery negative cable. Refer to Battery Cable.
2. Drain the engine coolant. Refer to Draining and Filling Cooling System.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
4. Remove the following coolant hoses:
5. Upper radiator hose. Refer to Radiator Hose Replacement.
6. Both heater hoses. Refer to Heater Hoses Replacement (Inlet/Outlet Hose).
7. Water pump inlet hose. Refer to Hot Water Bypass Valve Replacement in Cooling System.
8. Disconnect all electrical connectors and secure out of the way.
9. Remove the distributor. Refer to Distributor Replacement.
10. Use a twisting motion to remove the vacuum brake booster hose, if equipped.
11. Disconnect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement.
12. Remove the drive belt. Refer to Drive Belt Replacement.

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

13. Remove the Air Conditioning (A/C) compressor, if equipped, and set the A/C compressor aside. Refer to Compressor Replacement.





14. Remove the PCV valve.
15. Disconnect the Exhaust Gas Recirculation (EGR) pipe from the bracket and the front of the intake manifold. Refer to Secondary Air Injection Check Valve/Pipe Replacement.
16. Disconnect the fuel pipes from the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
17. Disconnect the electrical connector from the power steering pump.





18. Remove the power steering bracket using the following procedure:
- Remove the power steering pump. Refer to Power Steering Pump Replacement in Steering and Suspension.
- Remove the nut, then the bolts.
- Remove two nuts from the back of the power steering pump.
- Slide the power steering bracket forward, with the power steering pump still attached.
19. Disconnect the wiring bracket from the rear of the right cylinder head.
20. Remove the valve rocker arm covers. Refer to Valve Rocker Arm Cover Replacement.
21. Remove the intake manifold. Refer to Intake Manifold Replacement (Upper).
22. Clean all surfaces.


Installation Procedure





1. Install the intake manifold. Refer to Intake Manifold Installation.
2. Install the valve rocker arm covers Refer to Valve Rocker Arm Cover Installation (Right) and Valve Rocker Arm Cover Replacement.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the power steering bracket using the following procedure:
- Install the power steering bracket onto the stud.
- Install the nut onto the stud finger tight.
- Install the three bolts finger tight.
- Install the two nuts to the back of the power steering pump.
- Tighten the nuts and the bolts to 41 Nm (30 ft. lbs.).
- Install the power steering pump. Refer to Power Steering Pump Replacement in Steering and Suspension.
- Connect the electrical connector to the power steering pump.
- Connect the fuel pipes to the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
- Connect the wiring bracket to the rear of the right cylinder head.





4. Install the PCV valve.
5. Connect the Exhaust Gas Recirculation (EGR) valve pipe to the bracket and the front of the intake manifold. Refer to EGR Pipe Replacement.
6. Use a twisting motion to install the vacuum brake booster hose, if equipped.
7. Install AIR check valve (crossover) pipe, if equipped. Refer to Secondary Air Injection Check Valve/Pipe Replacement.





8. Install the Air Conditioning (A/C) compressor onto the power steering bracket. Refer to Compressor Replacement in Heating and Air Conditioning.
9. Install the drive belt. Refer to Drive Belt Replacement.
10. Connect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement.
11. Install the distributor. Refer to Distributor Replacement.
12. Connect all electrical connectors.





13. Install the following coolant hoses.
- Upper radiator hose. Refer to Radiator Hose Replacement in Cooling System.
- Both heater hoses. Refer to Heater Hoses Replacement (Inlet Hose - Outlet Hose) in Cooling System.
- Water pump inlet. Refer to Hot Water Bypass Valve Replacement in Cooling System.
- Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
- Fill the cooling system with coolant. Refer to Draining and Fitting Cooling System in Cooling System.
- Connect the battery negative cable. Refer to Battery Cable.