Intake Manifold Replacement - Lower
Removal Procedure
Important: You do not have to remove the upper intake manifold in order to remove the lower intake manifold.
1. Disconnect the battery negative cable. Refer to Battery Replacement.
2. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement.
3. Disconnect the accelerator control cable from the throttle shaft and the accelerator cable bracket. Refer to Accelerator Controls Cable Replacement.
4. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement.
5. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.
6. Disconnect the power brake booster vacuum hose.
7. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
8. Remove the radiator inlet hose at the water outlet. Refer to Radiator Hose Replacement in Cooling System.
9. Remove the heater hose from the intake manifold. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
10. Remove the water pump inlet hose form the intake manifold.
11. Disconnect the following electrical connectors:
^ The fuel meter body assembly (1)
^ The EVAP canister purge solenoid valve (2)
^ The Manifold Air Pressure (MAP) sensor (3).
12. Disconnect the following electrical connectors:
^ The Exhaust Gas Recirculation (EGR) valve (3)
^ The ignition coil (2)
^ The Ignition Control Module (ICM) (1)
^ The generator (4)
13. Disconnect the following electrical connectors:
^ The Idle Air Control (IAC) motor (3)
^ The Throttle Position (TP) sensor (2)
^ The A/C compressor cutoff switch, if equipped (5)
^ The A/C clutch switch, if equipped (1)
^ The Engine Coolant Temperature (ECT) sensor (4)
14. Remove the engine wiring harness clips from the brackets.
15. Move the engine wiring harness aside.
16. Remove the accelerator cable bracket from the throttle body and the intake manifold.
17. Remove the accelerator and the cruise control cable bracket from the throttle bracket.
Leave the accelerator and cruise control cables on the bracket.
18. Disconnect the PCV hose assembly from the intake manifold and the valve rocker arm cover.
19. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
20. Remove the spark plug wire harness retainer from the exhaust gas recirculation (EGR) valve inlet pipe.
21. Remove the clamp bolt for the EGR valve inlet pipe.
22. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
23. Remove the distributor. Refer to Distributor Replacement.
24. Disconnect the fuel supply and return pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
Important: Do not discharge the refrigerant.
25. Perform the following in order to remove the left front bolt for the intake manifold:
25.1. Remove the drive belt. Refer to Drive Belt Replacement.
25.2. Loosen the nut for the power steering pump rear bracket at the side of the engine.
25.3. Remove the secondary Air Injection (AIR) Reactor pipe bracket nut from the power steering pump rear bracket front stud, if equipped.
25.4. Remove the nut for the power steering pump rear bracket at the front of the engine.
25.5. Remove the bolts and the nut for the power steering pump mounting bracket.
25.6. Leave the A/C compressor, if equipped, and the power steering pump on the power steering pump mounting bracket.
25.7. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
26. Remove the lower intake manifold. Refer to Intake Manifold Removal.
27. Disassemble the intake manifold assembly if replacing the lower intake manifold. Refer to Intake Manifold Disassemble.
Important: Do not immerse the assembled intake manifold in cleaning solvent.
28. Clean all sealing surfaces. Refer to Intake Manifold Clean and Inspect.
Installation Procedure
1. Assemble the intake manifold assembly if replacing the lower intake manifold. Refer to Intake Manifold Assemble.
2. Install the lower intake manifold. Refer to Intake Manifold Installation.
3. Position the power steering pump mounting bracket.
4. Loosely install the power steering pump mounting bracket bolts and nuts.
Notice: Refer to Fastener Notice in Service Precautions.
5. Install the nut for the power steering pump rear bracket at the front of the engine.
^ Tighten the power steering pump mounting bracket bolts and the power steering pump rear bracket nuts to 41 Nm (30 ft. lbs.).
6. Install the AIR reactor pipe bracket nut to the power steering pump rear bracket front stud, if equipped.
^ Tighten the AIR reactor pipe bracket nut to 41 Nm (30 ft. lbs.).
7. Install the drive belt. Refer to Drive Belt Replacement.
8. Install the fuel supply and return pipes to the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
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 two reference marks on the crankshaft balancer (1) and (4) with the two alignment marks (2) and (3) on the front cover.
12. Install the spark plug. Refer to Spark Plug Replacement.
13. Install the distributor. Refer to Distributor Replacement.
14. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
15. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold.
15.1. Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
15.2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
15.3. Tighten the EGR valve inlet pipe clamp bolt 25 Nm (18 ft. lbs.).
16. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
17. Install the PCV hose assembly to the intake manifold and the valve rocker arm cover.
18. Install the accelerator cable and cruise control cable bracket to the throttle body.
^ Tighten the accelerator cable and cruise control bracket nuts to 9 Nm (80 inch lbs.).
19. Install the accelerator cable bracket to the intake manifold and the throttle body.
^ Tighten the accelerator cable bracket studs and nuts to 12 Nm (106 inch lbs.).
20. Position the engine wiring harness.
21. Install the engine wiring harness clips in the brackets.
22. Connect the following electrical connectors:
^ The idle air control (IAC) motor (3)
^ The throttle position (TP) sensor (2)
^ The A/C compressor cutoff switch, if equipped (5)
^ The A/C clutch switch, if equipped (1)
^ The engine coolant temperature (ECT) sensor (4)
23. Connect the following electrical connectors:
^ The fuel meter body assembly (1)
^ The EVAP canister purge solenoid valve (2)
^ The manifold air pressure (MAP) sensor (3)
24. Connect the following electrical connectors:
^ The exhaust gas recirculation (EGR) valve (3)
^ The ignition coil (2)
^ The ignition control module (ICM) (1)
^ The generator (4)
25. Connect the power brake booster vacuum hose.
26. Connect the vacuum hose to the intake manifold, if equipped with A/C.
27. Install the water pump inlet hose to the intake manifold.
28. Install the heater hose to the intake manifold. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
29. Install the radiator inlet hose to the water outlet. Refer to Radiator Hose Replacement in Cooling System.
30. Install the accelerator control cable to the bracket and the throttle shaft. Refer to Accelerator Controls Cable Replacement.
31. Install the cruise control cable, if equipped to the bracket and the throttle shaft. Refer to Cruise Control Cable Replacement.
32. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
33. Install the air cleaner outlet duct to the throttle body. Refer to Air Cleaner Outlet Duct Replacement.
34. Connect the battery negative cable. Refer to Battery Replacement.