Intake Manifold Replacement - Lower
Intake Manifold Replacement - LowerRemoval Procedure
1. Disconnect the battery negative cable.
2. Remove the engine cover.
3. Drain the cooling system.
4. Remove the air cleaner assembly.
5. Remove the air cleaner outlet duct from the throttle body assembly.
6. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket.
7. Perform this step if the vehicle is equipped with a cruise control. Disconnect the cruise control cable from the throttle shaft, and from the accelerator control cable bracket.
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. Remove the ground wire from the stud at the water outlet.
14. Remove the nut, and remove the engine wiring harness bracket from the stud, at the EVAP canister purge solenoid valve.
15. Move and secure the engine wire harness out of the way.
16. Remove the EVAP canister purge valve.
17. Remove the radiator inlet hose at the water outlet.
18. Remove the heater hose from the intake manifold.
19. Remove the water pump inlet hose from the intake manifold.
20. Disconnect the vacuum hose from the intake manifold.
21. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket.
22. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
23. Remove the distributor.
24. Disconnect the fuel supply, and disconnect the return pipes, at the rear of the intake manifold.
25. Remove the ignition control module (ICM).
26. In order to remove the front intake manifold bolt, perform the following steps:
26.1. Remove the drive belt.
26.2. Remove the A/C compressor side brace.
26.3. Loosen the nut for the power steering pump rear bracket.
26.4. Remove the oil filler tube bracket bolt and the oil filler tube.
26.5. Remove the bolts and the nut for the power steering pump mounting bracket.
26.6. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
26.7. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
27. Remove the lower intake manifold.
28. Clean all sealing surfaces and the intake manifold.
29. If the intake manifold requires replacement, refer to Intake Manifold Disassemble, and to Intake Manifold Assemble.
Installation Procedure
1. Install the lower intake manifold.
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 25 Nm (18 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.
7. Install the EVAP canister purge valve.
8. Install the fuel supply and return pipes to the rear of the intake manifold.
Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.
9. Remove the spark plug for number one cylinder.
10. Rotate the crankshaft until number one cylinder is in the compression stroke.
11. Align the 2 reference marks on the crankshaft balancer (1, 4) with the 2 alignment marks (2, 3) on the front cover.
12. Install the spark plug.
13. Install the distributor.
14. Install the ICM.
15. 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.).
16. Install the vacuum hose to the intake manifold.
17. 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.).
18. Install the water pump inlet hose to the intake manifold.
19. Install the heater hoses.
20. Install the radiator inlet hose to the water outlet.
21. Position the engine wiring harness.
22. 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)
23. Connect the following electrical connectors:
^ The manifold absolute pressure (MAP) sensor (4)
^ The EVAP canister purge solenoid valve (1)
24. Install the ground wire and the nut to the water outlet stud.
^ Tighten the ground wire nut to 19 Nm (14 ft. lbs.).
25. Install the nut and the engine wiring harness bracket to the stud for the EVAP canister purge valve.
^ Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.).
26. 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.).
27. 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.).
28. Install the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
29. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket.
30. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket.
31. Refill the cooling system.
32. Install air cleaner outlet duct to the throttle body.
33. Install the air cleaner assembly.
34. Connect the battery negative cable.
35. Install the engine cover.