Intake Manifold Removal
Intake Manifold Replacement - LowerRemoval 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.
2. Remove the engine cover.
3. Drain the cooling system.
4. Remove the retaining nut (1) from the air cleaner outlet.
5. Remove the air cleaner outlet duct (2) from the throttle body assembly.
6. Disconnect the harness connector of the Intake Air Temperature (IAT) sensor.
7. Loosen the air cleaner outlet duct from the Mass Air Flow (MAF) sensor.
8. Remove the air cleaner outlet duct.
9. Remove the air cleaner assembly.
10. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket.
11. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket.
12. Disconnect the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
13. Disconnect the following electrical connectors:
^ The Throttle Position (TP) sensor (1)
^ The Idle Air Control (IAC) motor (2)
^ The Engine Coolant Temperature (ECT) gage sensor (3)
^ The A/C high pressure switch (4), if equipped
14. Disconnect the following electrical connectors:
^ The fuel meter body assembly connector (1)
^ The EVAP canister purge solenoid valve (2)
^ The Manifold Absolute Pressure (MAP) sensor (3)
15. Disconnect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The EGR valve (2)
^ The Engine Coolant Temperature (ECT) sensor (3)
16. Remove the ground wire (4) from the stud at the water outlet.
17. Remove the radiator inlet hose at the water outlet.
18. Remove the heater hose from the intake manifold.
19. Remove the water pump inlet hose from the intake manifold.
20. Disconnect the A/C vacuum hose from the intake manifold.
21. Disconnect the power brake booster vacuum hose from the intake manifold.
22. Remove the power brake booster vacuum hose bracket and nut.
23. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
24. Remove the EVAP canister purge solenoid valve.
25. Remove the distributor.
26. Disconnect the fuel supply and the return pipes at the rear of the intake manifold.
27. Remove the Ignition Control Module (ICM).
28. Remove the spark plug wire harness retainer from the Exhaust Gas Recirculation (EGR) valve inlet pipe.
29. Remove the clamp bolt for the EGR valve inlet pipe.
30. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
31. In order to remove the front intake manifold bolt, perform the following:
31.1. Remove the auxiliary evaporator tube from the A/C compressor, if equipped.
31.2. Remove the drive belt.
31.3. Loosen the nut for the power steering pump rear bracket.
31.4. Remove the bolts and the nut for the power steering pump mounting bracket.
31.5. Leave the A/C compressor, if equipped, and the power steering pump on the bracket.
31.6. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
32. Remove the Engine Coolant Temperature (ECT) sensor wire connector (if equipped) from the engine wiring harness bracket.
33. Remove the lower intake manifold bolts.
Important: The intake manifold may be removed as an assembly.Do not remove the specific intake manifold components unless component service is required.Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed.
Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless service is required.
34. Remove the intake manifold assembly.
35. Remove and discard the lower intake manifold gaskets.
36. Clean all sealing surfaces and the intake manifold.
37. If the intake manifold requires replacement refer to Intake Manifold Disassemble.