Intake Manifold Replacement - Lower

Removal Procedure





1. Disconnect the battery negative cable. Refer to Battery Replacement in Starting and Charging.
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. Remove the radiator inlet hose at the water outlet.
7. Remove the heater hose from the intake manifold.
8. Remove the water pump inlet hose from the intake manifold.
9. Remove the ground wire from the stud at the water outlet.





10. Disconnect the accelerator control cable from the throttle shaft. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
11. Disconnect the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
12. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket.
13. Remove the accelerator control cable bracket from the throttle body and the intake manifold.





14. 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 Engine Coolant Temperature (ECT) gauge 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





15. In order to remove the front intake manifold bolt, perform the following:
15.1. Remove the drive belt.
15.2. Remove the A/C compressor side brace.
15.3. Loosen the nut for the power steering pump rear bracket.
15.4. Remove the oil filler tube bracket bolt and the oil filler tube.
15.5. Remove the bolts and the nut for the power steering pump mounting bracket.
15.6. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
15.7. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
16. Remove the distributor. Refer to Distributor Replacement in Powertrain Management.





17. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake and the exhaust manifolds.
18. Disconnect the fuel supply and the return pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.





19. Disconnect PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
20. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.





21. Remove the nut holding the A/C hose bracket to the intake manifold stud, if equipped.
22. Remove the nut holding the engine wiring harness bracket to the intake manifold stud.
23. Remove bolts holding the ignition control module (ICM) and set the ICM aside.





24. Remove the nut and the engine wiring harness bracket from the stud at the EVAP canister purge solenoid valve.
25. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Powertrain Management.





26. Remove the lower intake manifolds bolts.
27. Remove the lower intake manifold.
28. Clean all sealing surfaces.

Installation Procedure





1. Install the lower intake manifold.





2. Install the EVAP canister purge solenoid valve.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the nut and the engine wiring harness bracket to the stud for the EVAP canister purge solenoid valve.
Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.).
4. Install the ICM. Refer to Ignition Coil and ICM Replacement (4.3L) in Powertrain Management.
5. Install the fuel supply and return pipes to the rear of the intake manifold.





6. 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.).
7. 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.).





8. Install the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
9. Install the vacuum hose to the intake manifold, if equipped with A/C.





10. Install the exhaust gas recirculation (EGR) valve inlet pipe to the intake and the exhaust manifolds.
^ Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
^ Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
^ Tighten the EGR valve inlet pipe clamp bolt to 25 Nm (18 ft. lbs.).
11. Install the distributor.





12. Reposition the power steering pump mounting bracket.
13. 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.).
14. Install A/C compressor side brace and bolts.
14.1. Tighten the A/C compressor side brace bolt to 50 Nm (37 ft. lbs.)
14.2. Tighten the side brace bolt to the generator bracket to 25 Nm (18 ft. lbs.).
15. Install the oil filler tube and bolt.
Tighten the oil filler tube bolt to 25 Nm (18 ft. lbs.).
16. Install the drive belt.
17. Install the ground wire and the nut to the water outlet stud.
Tighten the ground wire nut to 10 Nm (88 inch lbs.).





18. 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 Engine Coolant Temperature (ECT) gauge 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





19. 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.).
20. 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.).
21. Install the cruise control cable, if equipped.
22. Install the accelerator control cable to the throttle shaft.





23. Install the water pump inlet hose to the intake manifold.
24. Install the heater hoses.
25. install the radiator inlet hose to the water outlet.
26. Refill the cooling system.
27. Install air cleaner outlet duct to the throttle body.
28. Install the air cleaner assembly.
29. Connect the battery negative cable.
30. Install the engine cover.