Lower Intake Manifold Replacement

Lower Intake Manifold Replacement

Removal Procedure

Important:
^ The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.
^ It is not necessary to remove the upper intake manifold in order to remove the lower intake manifold.
^ 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.





1. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (Vac-N-Fill).
2. Remove the fuel pipes/hoses.
3. Remove the distributor.
4. Disconnect the evaporative emission (EVAP) canister harness from the purge solenoid valve.





5. Remove the heater hose clamp (1).





6. Open the heater outlet hose clamp and remove the hose from the intake manifold.





7. Open the heater inlet hose clamp and remove the hose from the water pump.
8. Reposition the heater inlet and outlet hoses.





9. Disconnect the cruise control cable from the throttle body lever, if equipped.
10. Remove the cruise control cable from the accelerator control cable bracket, if equipped.





11. Remove the accelerator cable from the throttle body lever.





12. Remove the accelerator cable from the accelerator control cable bracket.





13. Disconnect the following electrical connectors:
^ The air conditioning (A/C) compressor clutch (1), if equipped
^ The A/C pressure switch (4), if equipped
14. Remove the engine wiring harness clip (3) from the accelerator control cable bracket.





15. Remove the accelerator control cable bracket nuts.
16. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
17. Reposition and secure the bracket and cables out of the way.





18. Disconnect the following electrical connectors:
^ The throttle position (TP) sensor (1)
^ The idle air control (IAC) motor (2)
^ The control port injector module (3)
19. Remove the engine wiring harness clip bolt (4).





20. Disconnect the following electrical connectors:
^ The EVAP canister purge solenoid valve (1)
^ The manifold absolute pressure (MAP) sensor (2)





21. Remove the engine wiring harness bracket nuts.
22. Remove the engine wiring harness bracket.





23. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.





24. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
25. Remove the stud holding the engine wiring harness bracket.
26. Reposition the engine wiring harness with the bracket aside.





27. Remove the positive crankcase ventilation (PCV) valve hose from the valve cover and rocker cover.





28. Disconnect the power brake booster vacuum hose from the vacuum fitting.





29. Reposition the radiator inlet hose clamps.
30. Remove the radiator inlet hose from the thermostat housing.





31. Reposition the water pump inlet hose clamps.
32. Remove the water pump inlet hose.





33. In order to remove the front intake manifold bolt, perform the following:
1. Remove the drive belt.
2. Loosen the power steering (P/S) pump rear bracket nut.
3. Remove the P/S pump rear bracket front nut.
4. Remove the bolts and the nut for the P/S pump bracket.
5. Leave the A/C compressor, if equipped, and the P/S pump on the bracket.
6. Slide the P/S pump bracket forward to access the front intake manifold bolt.





34. Remove the intake manifold-lower bolts.
35. Remove the intake manifold.
36. Remove and discard the intake manifold gaskets.
37. Clean and inspect the intake manifold-lower, if necessary. Refer to Intake Manifold Cleaning and Inspection.

Installation Procedure

Notice: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage.





1. Apply a 4.0 mm (0.157 inch) patch of adhesive to the cylinder head side of the intake manifold gasket at each end. Refer to Sealers, Adhesives, and Lubricants for the correct part number.

Important: The intake manifold gasket must be installed while the adhesive is still wet to the touch.

2. Install the intake manifold gasket onto the cylinder head. Use the gasket locating pins in order to properly seat the gasket.





3. Important: The intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch.

Apply a 5 mm (0.197 inch) bead of adhesive to the front top of the engine block. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
4. Extend the adhesive bead 13 mm (0.50 inch) up onto each intake manifold gasket.





5. Apply a 5 mm (0.197 inch) bead of adhesive to the rear top of the engine block. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
6. Extend the adhesive bead 13 mm (0.50 inch) up onto each intake manifold gasket.





7. Install the intake manifold.
8. If reusing the old fasteners, apply threadlock to the threads of the intake manifold - lower bolts. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
9. Install the intake manifold - lower bolts.





10. 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.

Notice: Refer to Fastener Notice in Service Precautions.

Tighten the intake manifold-lower bolts in the sequence shown.
1. Tighten the bolts a first pass to 3 Nm (27 inch lbs.).
2. Tighten the bolts a second pass to 12 Nm (106 inch lbs.).
3. Tighten the bolts a final pass to 15 Nm (11 ft. lbs.).





11. Slide the P/S pump bracket rearward.
12. Install the bolts and the nut for the P/S pump bracket.
13. Install the P/S pump rear bracket front nut.
14. Tighten the P/S pump rear bracket nut.
Tighten the bolts and nuts to 41 Nm (30 ft. lbs.).
15. Install the drive belt.





16. Install the water pump inlet hose.
17. Position the water pump inlet hose clamps.





18. Install the radiator inlet hose to the thermostat housing.
19. Position the radiator inlet hose clamps.





20. Connect the power brake booster vacuum hose to the vacuum fitting.





21. Install the PCV valve hose to the valve cover and rocker cover.





22. Position the engine wiring harness and bracket.
23. Install the engine wiring harness bracket stud.
Tighten the stud to 25 Nm (18 ft. lbs.).
24. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
Tighten the nut to 9 Nm (80 inch lbs.).





25. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head.
Tighten the nut to 16 Nm (12 ft. lbs.).





26. Install the engine wiring harness bracket.
27. Install the engine wiring harness bracket nuts.
Tighten the nuts to 12 Nm (106 inch lbs.).





28. Connect the EVAP canister harness to the purge solenoid valve.





29. Connect the following electrical connectors:
^ The EVAP canister purge solenoid valve (1)
^ The MAP sensor (2)





30. Connect the following electrical connectors:
^ The TP sensor (1)
^ The IAC motor (2)
^ The control port injector module (3)
31. Install the engine wiring harness clip bolt (4).
Tighten the bolt to 9 Nm (80 inch lbs.).





32. Position the bracket and cables.
33. Install the accelerator control cable bracket with the cables attached, to the throttle body.
34. Install the accelerator control cable bracket nuts.
Tighten the nuts to 9 Nm (80 inch lbs.).





35. Connect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The A/C pressure switch (4), if equipped
36. Install the engine wiring harness clip (3) to the accelerator control cable bracket.





37. Install the accelerator cable to the accelerator control cable bracket.





38. Install the accelerator cable to the throttle body lever.





39. Install the cruise control cable to the accelerator control cable bracket, if equipped.
40. Connect the cruise control cable to the throttle lever, if equipped.





41. Position the heater inlet and outlet hoses.
42. Open the heater inlet hose clamp and install the hose to the water pump.





43. Open the heater out let hose clamp and install the hose to the intake manifold.





44. Install the heater hose clamp (1).
45. Install the fuel pipes/hoses.
46. Install the distributor.
47. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (Vac-N-Fill).