Intake Manifold Replacement Lower

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable.
2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.



3. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
4. Remove the upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
5. Remove the water pump inlet hose. Refer to Water Pump Replacement in Engine Cooling.
6. Disconnect all electrical connectors and secure out of way.



7. Remove the distributor. Refer to Distributor Replacement in Engine Electrical.
8. Use a twisting motion to remove the vacuum brake booster hose, if equipped.



9. Disconnect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Control Cable Replacement in Engine Controls.



10. Remove the drive belt. Refer to Drive Belt Replacement .




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

11. Remove the air conditioning (A/C) compressor, if equipped, and set the A/C compressor aside. Refer to Air Conditioning Compressor Replacement in HVAC.



12. Remove the exhaust gas recirculation (EGR) pipe from the intake and exhaust manifolds.
13. Remove the PCV valve.



14. Disconnect the fuel pipes from the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.



15. Remove the power steering bracket using the following procedure:

15.1.

Remove the power steering pump pulley. Refer to Power Steering Pump Replacement in Steering.

15.2.

Remove the nut, then the bolts.

15.3.

Remove two nuts from the back of the power steering pump.

15.4.

Slide the power steering pump mounting bracket forward, with the power steering pump still attached.

16. Disconnect the wiring bracket from the rear of the right cylinder head.



17. Remove one valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .



18. Remove the intake manifold bolts.
19. Remove the intake manifold. Refer to Intake Manifold Removal .
20. Clean the gasket surfaces.

1. Install the intake manifold. Refer to Intake Manifold Installation .



2. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .



3. Install the power steering bracket using the following procedure:

3.1.	Install the power steering bracket onto the stud.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3.2.	Install the nut onto the stud finger tight.

3.3.	Install the three bolts finger tight.

3.4.	Install the two nuts to the back of the power steering pump.

Tighten
Tighten the nuts and the bolts to 44 N·m (32 lb ft).




4. Install the power steering pump pulley. Power Steering Pump Replacement in Steering.



5. Connect the fuel pipes to the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
6. Connect the wiring bracket to the rear of the right cylinder head.



7. Install the PCV valve.



8. Install the exhaust gas recirculation (EGR) pipe to the intake and exhaust manifolds.

Tighten

1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N·m (18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N·m (22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N·m (18 lb ft).
9. Use a twisting motion to install the vacuum brake booster hose, if equipped.



10. Install the air conditioning (A/C) compressor, if equipped. Refer to Air Conditioning Compressor Replacement in HVAC.



11. Install the drive belt. Refer to Drive Belt Replacement .



12. Connect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Control Cable Replacement in Engine Controls.



13. Install the distributor. Refer to Distributor Replacement in Engine Electrical.
14. Connect all electrical connectors.



15. Install the upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
16. Install water pump inlet hose. Refer to Water Pump Replacement in Engine Cooling.
17. Install the air cleaner outlet duct to the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
18. Fill the cooling system with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
19. Connect the battery negative cable.

Tighten
Tighten the terminal bolt to 12 N·m (106 lb in).

Intake Manifold Replacement Upper

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable.
2. Remove the PCV tube from the air cleaner outlet duct.
3. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.



4. Disconnect the accelerator control and cruise control cables (if equipped). Refer to Accelerator Control Cable Replacement in Engine Controls.
5. Remove the accelerator control cable bracket and set it aside.
6. Remove the following electrical connectors:

•	The SCPI injector harness connector

•	The EVAP canister purge solenoid valve

•	The ignition coil

•	The ignition control module (ICM)

•	The generator

•	The idle air control (IAC) motor

•	The throttle position (TP) sensor

•	The oxygen (O²) sensor

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT) sensor

•	The oil pressure sensor




7. Disconnect the fuel pipes from the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
8. Remove the AIR check valve crossover pipe, if equipped.
9. Remove the distributor cap and position the distributor cap out of the way.



10. Remove the PCV valve hose assembly.
11. Remove the engine wiring harness bracket from the upper intake manifold.
12. Remove the EVAP canister purge solenoid valve.
13. Remove the studs holding the upper intake manifold to the lower intake manifold.



14. Remove the upper intake manifold.

Refer to Intake Manifold Disassemble

15. Clean all surfaces.

Refer to Intake Manifold Clean and Inspect

1. Install the upper intake manifold. Refer to Intake Manifold Assemble
2. Install the EVAP canister purge solenoid valve.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the engine wiring harness bracket to the upper intake manifold.

Tighten
Tighten the nut to 12 N·m (106 lb in).




4. Install the PCV valve hose assembly.
5. Install the distributor cap.



6. Connect the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.



7. Install the AIR check valve crossover pipe, if equipped.
8. Connect the electrical connectors.
9. Install the accelerator control cable bracket.



10. Connect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Control Cable Replacement in Engine Controls.



11. Install the vacuum brake booster hose, if equipped.
12. Install air cleaner outlet duct to the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
13. Install the PCV tube to the air cleaner outlet duct.
14. Connect the battery negative cable.

Tighten
Tighten the terminal bolt to 12 N·m (106 lb in).