Intake Manifold Replacement Upper

1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
3. Disconnect the PCV tube from the air inlet duct.
4. Remove the air inlet duct from the throttle body.
5. Disconnect the following electrical connectors:

•	The throttle position (TP) sensor

•	The idle air control (IAC) motor

•	The fuel meter body assembly connector

•	The manifold absolute pressure (MAP) sensor

•	The EVAP canister purge solenoid valve




6. Remove the PCV valve hose from the intake manifold and the valve rocker arm cover.



7. Disconnect the A/C vacuum hose from the intake manifold, if equipped with A/C.
8. Remove the vacuum brake booster hose bracket from the upper intake stud.
9. Disconnect the vacuum brake booster hose from the intake manifold.
10. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.



11. Disconnect the accelerator control cable from the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
12. Disconnect the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
13. Remove the studs and nuts for the accelerator control cable bracket.
14. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
15. Remove the distributor cap. Refer to Distributor Replacement in Engine Electrical.
16. Remove the ignition coil module. Refer to Ignition Coil and Ignition Coil Module Replacement in Engine Electrical.
17. Remove the fuel lines from the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
18. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement in Engine Controls.



19. Remove the upper intake manifold. Refer to Intake Manifold Disassemble .
20. Clean all sealing surfaces. Refer to Intake Manifold Clean and Inspect .

1. Install the upper intake manifold. Refer to Intake Manifold Assemble .
2. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement in Engine Controls.
3. Install the fuel lines to the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
4. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.
5. Install the ignition coil module. Refer to Ignition Coil and Ignition Coil Module Replacement in Engine Electrical.




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.

6. Install the accelerator control and cruise control cable bracket, studs, and nuts to the throttle body and the intake manifold.

Tighten
Tighten the cable bracket nuts and bolts to 12 N·m (106 lb in).

7. Install the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
8. Install the accelerator control cable to the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
9. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.



10. Connect the vacuum brake booster hose to the intake manifold.
11. Install the vacuum brake booster hose bracket and nut on the intake manifold stud.

Tighten
Tighten the nut to 11 N·m (97 lb in).

12. Connect the A/C vacuum hose to the intake manifold, if equipped with A/C.



13. Connect the PCV valve hose to the intake manifold and the valve rocker arm cover.
14. Connect the following electrical connectors:

•	The throttle position (TP) sensor

•	The idle air control (IAC) motor

•	The fuel meter body assembly connector

•	The manifold absolute pressure (MAP) sensor

•	The EVAP canister purge solenoid valve




15. Install the air inlet duct to the throttle body assembly.
16. Connect the PCV tube to the air inlet duct.
17. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
18. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.

Intake Manifold Replacement Lower

1. Disconnect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.
2. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the upper fan shroud section. Refer to Fan Shroud Replacement in Engine Cooling.
5. Disconnect the PCV tube.
6. Remove the air inlet duct from the throttle body assembly.



7. Remove the radiator inlet hose at the water outlet. Refer to Radiator Hose Replacement in Engine Cooling.
8. Remove the generator. Refer to Generator Replacement in Engine Electrical.
9. Remove the heater hose from the intake manifold. Refer to Heater Hoses Replacement in Heating and Ventilation (Non-A/C).
10. Remove the water inlet hose from the intake manifold.
11. Remove the ground wire from the stud for the water outlet.



12. Remove the accelerator control cable from the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
13. Disconnect the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
14. Remove the accelerator and cruise control cables bracket from the throttle body and the intake manifold.
15. Disconnect the following electrical connectors:

•	The fuel meter body assembly

•	The EVAP canister purge solenoid valve.

•	The idle air control (IAC) motor

•	The throttle position (TP) sensor

•	The manifold absolute pressure (MAP) sensor

•	The A/C compressor high pressure switch, if equipped

•	The A/C clutch switch, if equipped

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT) sensor




16. In order to remove the front lower intake manifold bolt, perform the following:

16.1.

Remove the drive belt. Refer to Drive Belt Replacement .

16.2.

Loosen the power steering pump rear bracket side nut.

16.3.

Remove he power steering pump rear bracket front nut.

16.4.

Remove the bolts and the nut for the power steering pump mounting bracket.

16.5.

Leave the A/C compressor, if equipped, and the power steering pump on the bracket.

16.6.

Slide the power steering pump mounting bracket forward to access the bolt at the front of the intake manifold.




17. Remove the distributor. Refer to Distributor Replacement in Engine Electrical.
18. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake manifold and the exhaust manifold.



19. Disconnect the fuel supply and return pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
20. Disconnect PCV valve hose from the intake manifold and the valve rocker arm cover.



21. Disconnect the A/C vacuum hose from the intake manifold, if equipped with A/C.
22. Disconnect the vacuum brake booster hose from the intake manifold.
23. Remove the vacuum brake booster hose bracket.
24. Remove bolts holding the ignition control module (ICM) and set the ICM aside. Refer to Ignition Coil and Ignition Coil Module Replacement in Engine Electrical.



25. Disconnect the EVAP canister purge solenoid valve hose.



26. Remove the lower intake manifold bolts.
27. Remove the lower intake manifold. Refer to Intake Manifold Removal .
28. Clean all sealing surfaces. Refer to Intake Manifold Clean and Inspect .

Notice: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.

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



2. Connect the EVAP canister purge solenoid valve pipe.
3. Install the ICM. Refer to Ignition Coil and Ignition Coil Module Replacement in Engine Electrical.
4. Install the fuel supply and return pipes to the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.



5. Install the PCV valve hose to valve rocker arm cover and the valve rocker arm cover.



6. Connect the A/C vacuum hose to the intake manifold, if equipped with A/C.
7. Connect the vacuum brake booster hose to the intake manifold.

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.

8. Install the vacuum brake booster hose bracket and nut to the intake manifold stud.

Tighten
Tighten the bracket nut to 11 N·m (97 lb in).




9. Install the exhaust gas recirculation (EGR) valve inlet pipe to the intake manifold and the exhaust manifold.

Tighten

•	Tighten the EGR valve inlet pipe intake manifold nut to 25 N·m (18 lb ft).

•	Tighten the EGR valve inlet pipe clamp bolt to 25 N·m (18 lb ft).

•	Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N·m (22 lb ft).





Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center.

10. Remove the spark plug for number one cylinder.
11. Rotate the crankshaft until number one cylinder is in the compression stroke.
12. Align the two reference marks on the crankshaft balancer (1) and (4) with the two alignment marks (2) and (3) on the front cover.
13. Install the spark plug. Refer to Spark Plug Replacement in Engine Electrical.
14. Install the distributor. Refer to Distributor Replacement in Engine Electrical.



15. Reposition the power steering pump mounting bracket.
16. Install the three bolts and the nut for the power steering pump mounting bracket.
17. Install the front nut for the power steering pump rear bracket

Tighten
Tighten the power steering pump mounting bracket bolts, the nut, and the power steering pump rear bracket nuts to 41 N·m (30 lb ft).

18. Install the drive belt. Refer to Drive Belt Replacement .
19. Install the ground wire to the water outlet stud.

Tighten
Tighten the nut to 10 N·m (88 lb in).

20. Connect the following electrical connectors:

•	The fuel meter body assembly

•	The EVAP canister purge solenoid valve

•	The idle air control (IAC) motor

•	The throttle position (TP) sensor

•	The manifold absolute pressure (MAP) sensor

•	The A/C compressor high pressure switch

•	The A/C clutch switch

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT) sensor




21. Install the accelerator control cable bracket, bolts, and nuts to the intake manifold and the throttle body.

Tighten
Tighten the nuts and bolts to 12 N·m (106 lb in).

22. Install the accelerator control cable to the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
23. Install the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.



24. Install the water inlet hose to the intake manifold.
25. Install the heater hoses. Refer to Heater Hoses Replacement in Heating and Ventilation (Non-A/C).
26. Install the generator. Refer to Generator Replacement in Engine Electrical.
27. Install the radiator inlet hose to the water outlet. Refer to Radiator Hose Replacement in Engine Cooling.
28. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.



29. Install air inlet duct to the throttle body.
30. Connect the PCV tube.
31. Install the upper fan shroud section. Refer to Fan Shroud Replacement in Engine Cooling.
32. Connect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.
33. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.