Intake Manifold Removal
Intake Manifold Replacement - LowerRemoval Procedure
Important: You do not have to remove the upper intake manifold in order to remove the lower intake manifold.
1. Disconnect the battery negative cable.
2. Drain the cooling system.
3. Separate the MAF/IAT sensor assembly and the air inlet tube by loosening the hose clamp.
4. Disconnect the PCV hose from the air cleaner outlet duct.
5. Remove the air inlet tube and resonator retaining wing nut.
6. Remove the air inlet tube and resonator from the throttle body by pivoting the air inlet tube and resonator upward until the hinge clip releases from the lip on the throttle body.
7. Remove the accelerator cable from the cable routing bracket.
8. Remove the accelerator cable from the throttle body lever.
9. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket at the side of the throttle body.
10. Remove the engine wiring harness and clip from the accelerator control cable bracket.
11. Remove the accelerator control cable bracket with the accelerator control cable and the cruise control cable from the throttle body.
12. Move and secure the accelerator control cable bracket with the cables out of the way.
13. Disconnect the secondary air injection (AIR) crossover pipe from the AIR pipe assemblies, if equipped.
14. Remove the AIR crossover pipe, if equipped.
15. Disconnect 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)
16. 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)
17. 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)
18. Remove the nut holding the engine wiring harness bracket to the EVAP purge solenoid valve stud.
19. Remove the nut holding the ground wire to the engine wiring harness bracket stud at the rear of the right cylinder head.
20. Remove the stud holding the engine wiring harness bracket.
21. Remove the two nuts holding the engine wiring harness bracket to the upper intake manifold studs.
22. Remove the engine wiring harness bracket from the studs.
23. Move the engine wiring harness with the brackets aside.
24. Remove the radiator inlet hose from the thermostat housing.
25. Remove the water pump inlet hose from the intake manifold.
26. Remove the heater hoses from the engine.
27. Remove the distributor.
28. Disconnect the fuel supply and return pipes at the rear of the intake manifold.
29. Disconnect PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
30. Disconnect the power brake booster vacuum hose from the intake manifold.
31. Disconnect the hose to the EVAP canister purge solenoid valve.
32. Remove the spark plug wire harness retainer from the Exhaust Gas Recirculation (EGR) valve inlet pipe.
33. Remove the clamp bolt for the EGR valve inlet pipe.
34. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
35. In order to remove the front intake manifold bolt, perform the following:
35.1. Remove the drive belt.
35.2. Loosen the power steering pump rear bracket side nut.
35.3. Remove the power steering pump rear bracket front nut.
35.4. Remove the bolts and the nut for the power steering pump mounting bracket.
35.5. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
35.6. Slide the power steering pump mounting bracket forward to access the bolt at the front of the intake manifold.
36. Remove the Engine Coolant Temperature (ECT) sensor wire connector (if equipped) from the engine wiring harness bracket.
37. Remove the lower intake manifold bolts.
Important: The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.
Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed.
Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless service is required.
38. Remove the intake manifold assembly.
39. Remove and discard the lower intake manifold gaskets.
Important: Do not immerse the assembled intake manifold in cleaning solvent.
40. Clean the lower intake manifold in cleaning solvent.
41. Dry the lower intake manifold with compressed air.
42. Inspect the lower intake manifold for the following:
^ Damage to the gasket sealing surfaces (1, 2, 3).
^ Restricted Exhaust Gas Recirculation (EGR) system passages (4)
^ Restricted cooling system passages (5)
^ Cracks or damage
^ Damage to the threaded bolt holes
43. If the intake manifold requires replacement refer to Intake Manifold Disassemble and Intake Manifold Assemble.