Intake Manifold: Service and Repair

1. Disable airbag system as described under MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING, then relieve fuel pressure as outlined under MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
2. Disconnect battery ground cable, then drain cooling system.
3. Remove air cleaner.
4. Remove drive belts.
5. Disconnect spark plug wires from spark plugs.
6. Remove two upper power steering pump bracket bolts and loosen lower nuts.
7. Remove distributor cap, wires and conduit.
8. Disconnect heater hose from thermostat housing.
9. Disconnect electrical connectors from: distributor, oil pressure switch, coolant sensor and EGR solenoid.
10. Remove distributor.
11. Disconnect cables from: accelerator, cruise control and transaxle throttle valve.
12. Disconnect fuel lines from throttle body.
13. Disconnect upper radiator hose from thermostat housing.
14. Remove fuel line brackets from transaxle and position fuel lines aside.
15. Remove cruise control servo bracket from intake manifold.
16. Remove vacuum line bracket from engine lift brackets.
17. Disconnect vacuum supply line from throttle body.
18. Disconnect transaxle modulator vacuum line.
19. Remove belt tensioner and power steering pump and bracket assembly and position aside.
20. Disconnect alternator electrical connectors and remove alternator.
21. Disconnect AIR management solenoid electrical connectors.
22. Remove AIR management valves and bracket assembly.
23. Disconnect electrical connectors from: ISC, TPS, fuel injectors, MAT sensor, oxygen sensor and throttle body base warmer.
24. Disconnect MAP hose.
25. Remove EGR solenoid and bracket assembly.
26. Remove rocker arm covers.
27. Remove rocker arm support assemblies.
28. Remove triangular seals.
29. Remove pushrods. Pushrods must be installed in original locations.
30. Remove idler pulley.
31. Remove power steering pipe and AIR pipe brackets from right side cylinder head.
32. Remove alternator mounting bracket.
33. Remove right front engine lift bracket bolt and position bracket aside.
34. Remove oil filter.
35. Remove right rear engine lift bracket.
36. Remove intake manifold bolts, noting position for installation.
37. Remove intake manifold from vehicle.

Intake Manifold Torque Sequence:

38. Reverse procedure to install. Install and torque manifold bolts to specifications in sequence shown in Fig. 5.
39. Rearm airbag system as described under MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING.