Intake Manifold Replacement Lower

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable. Refer to Battery Cable in Engine Electrical.
2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.



3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
4. Remove the following coolant hoses:

•	Upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.

•	Both heater hoses. Refer to Heater Hoses Replacement in HVAC.

•	Coolant by-pass hose. Refer to Heater Water Bypass Valve Replacement in HVAC.

5. Disconnect all electrical connectors.
6. Remove the distributor. Refer to Distributor Replacement in Engine Electrical.
7. Use a twisting motion to remove the vacuum brake booster hose, if equipped.
8. Disconnect the throttle cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement in Engine Controls.
9. Remove the drive belt. Refer to Drive Belt Replacement .




Important: It is not necessary to discharge the A/C refrigerant.

10. Remove the air conditioning (A/C) compressor, if equipped, and set it aside. Refer to Refrigerant Recovery and Recharging in HVAC.



11. Disconnect the exhaust gas recirculation (EGR) pipe from the bracket and the front of the intake manifold. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.
12. Remove the PCV valve.
13. Disconnect the fuel pipes from the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
14. Disconnect the electrical connector from the power steering pump.



15. Remove the power steering pump mounting bracket using the following procedure:

•	Remove the power steering pump pulley. Refer to Power Steering Pump Replacement in Steering.

•	Remove the nut, then the bolts.

•	Remove two nuts from the back of the power steering pump.

•	Slide the power steering pump mounting bracket forward, with the power steering pump still attached.

16. Disconnect the wiring bracket from the rear of the right cylinder head.
17. Remove one valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .



18. Remove the intake manifold bolts.
19. Remove the intake manifold.

Refer to Intake Manifold Removal .

20. Clean all surfaces.

Refer to Intake Manifold Clean and Inspect .

1. Install the intake manifold. Refer to Intake Manifold Installation .
2. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the power steering pump bracket using the following procedure:

•	Install the power steering pump bracket onto the stud.

•	Install the nut onto the stud finger tight.

•	Install the three bolts finger tight.

•	Install the two nuts to the back of the power steering pump.

•	Install the three bolts.

Tighten
Tighten the nuts and the bolts to 41 N·m (30 lb ft).

•	Install the power steering pump pulley. Refer to Power Steering Pump Replacement in Steering.

•	Connect the electrical connector to the power steering pump.

•	Connect the fuel pipes to the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.

•	Connect the wiring bracket to the rear of the right cylinder head.

•	Install the PCV valve.




4. Connect the exhaust gas recirculation (EGR) pipe to the bracket and the front of the intake manifold. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.
5. Use a twisting motion to install the vacuum brake booster hose, if equipped.
6. Install the air conditioning (A/C) compressor, if equipped. Refer to Refrigerant Recovery and Recharging in HVAC.
7. Install the drive belt. Refer to Drive Belt Replacement .
8. Connect the throttle cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement in Engine Controls.
9. Install the distributor. Refer to Distributor Replacement in Engine Electrical.
10. Connect all electrical connectors.
11. Install the following coolant hoses:

•	Upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.

•	Both heater hoses. Refer to Heater Hoses Replacement in Engine Cooling.

•	Coolant by-pass hose. Refer to Heater Water Bypass Valve Replacement

12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
13. Fill the engine cooling system with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
14. Connect the battery negative cable. Refer to Battery Cable in Engine Electrical.

Intake Manifold Replacement Upper

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable. Refer to Battery Cable in Engine Electrical.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
3. Remove the vacuum brake booster hose, if equipped.
4. Disconnect the throttle and cruise control cables (if equipped). Refer to Accelerator Controls Cable Replacement in Engine Controls.
5. Remove the throttle cable bracket and set it aside.
6. Remove the following electrical connectors:

•	The SCPI injector harness connector

•	The canister purge solenoid

•	The ignition coil

•	The ignition control module (ICM)

•	The generator

•	The idle air control (IAC) motor

•	The oxygen (O² sensor)

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT) sensor

7. Disconnect the fuel pipes from the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
8. Remove the distributor cap and reposition it out of the way. Refer to Distributor Replacement in Engine Electrical.
9. Remove the PCV valve.



10. Remove the wiring support bracket at the rear of the manifold.
11. Remove the canister purge valve.
12. Remove the studs holding the upper intake manifold.
13. Remove the upper intake manifold. Refer to Intake Manifold Disassemble .
14. Clean all surfaces. Refer to Intake Manifold Clean and Inspect .

1. Install the upper intake manifold.

Refer to Intake Manifold Assemble .

2. Install the canister purge valve.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the wiring support bracket at the rear of the manifold.

Tighten
Tighten the nut to 12 N·m (106 lb in).

4. Install the PCV valve.
5. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.
6. Connect the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
7. Connect the electrical connectors.
8. Install the throttle cable bracket.
9. Connect the throttle cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement in Engine Controls.
10. Install the vacuum brake booster hose, if equipped.
11. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
12. Connect the battery negative cable. Refer to Battery Cable in Engine Electrical.