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 Negative Cable Disconnection and Connection .
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the upper intake. Refer to Upper Intake Manifold Replacement .



4. Disconnect the A/C compressor (1) and the exhaust gas recirculation (EGR) connector (2).
5. Remove the ground wire (4) from the stud at the water outlet.



6. Remove the radiator inlet hose at the water outlet. Refer to Radiator Inlet Hose Replacement .
7. Remove the heater hose from the intake manifold. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .
8. Remove the water pump inlet hose from the intake manifold.



9. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
10. Remove the distributor. Refer to Distributor Replacement .
11. Remove the spark plug wire harness retainer from the EGR valve inlet pipe.



12. In order to remove the front intake manifold bolt, perform the following:

12.1.

Remove the A/C compressor discharge hose from the vehicle. Refer to Discharge Hose Replacement .

12.2.

Remove the A/C compressor suction hose from the vehicle. Refer to Suction Hose Replacement .

12.3.

Remove the drive belt. Refer to Drive Belt Replacement .

12.4.

Loosen the nut for the power steering pump rear bracket.

12.5.

Remove the bolts and the nut for the power steering pump mounting bracket.

12.6.

Leave the A/C compressor, if equipped, and the power steering pump on the bracket.

12.7.

Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.




13. Remove the engine coolant temperature (ECT) sensor wire connector, if equipped, from the engine wiring harness bracket.
14. 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.
15. Remove the intake manifold assembly.
16. Remove and discard the lower intake manifold gaskets.
17. Clean all sealing surfaces and the intake manifold. Refer to Intake Manifold Cleaning and Inspection .
18. If the intake manifold requires replacement refer to Intake Manifold Disassemble and Intake Manifold Assemble .

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

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

2. Install the lower intake manifold gasket onto the cylinder head.

Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.





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

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



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



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

Notice: Refer to Fastener Notice in the Preface section.




10. Tighten the lower intake manifold bolts.

Tighten

1. Tighten the bolts on the first pass in sequence (1-8) to 3 N·m (27 lb in).
2. Tighten the bolts on the second pass in sequence (1-8) to 12 N·m (106 lb in).
3. Tighten the bolts on the final pass in sequence (1-8) to 15 N·m (11 lb ft).



11. Position the power steering pump mounting bracket.
12. Install the power steering pump mounting bracket, 3 bolts and the nut.

Tighten

•	Tighten the power steering pump mounting bracket bolts and the nut to 41 N·m (30 lb ft).

•	Tighten the power steering pump rear bracket nut to 41 N·m (30 lb ft).

•	Tighten the power steering pump mounting bracket bolts and the nut and the power steering pump rear bracket nut to 41 N·m (30 lb ft).

13. Install the drive belt. Refer to Drive Belt Replacement .
14. Install the A/C compressor discharge hose from the vehicle. Refer to Discharge Hose Replacement .
15. Install the A/C compressor suction hose from the vehicle. Refer to Suction Hose Replacement .




Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center (TDC).

16. Remove the spark plug for number one cylinder.
17. Rotate the crankshaft until number one cylinder is in the compression stroke.
18. Align the 2 reference marks on the crankshaft balancer (1) and (4) with the 2 alignment marks (2) and (3) on the front cover.
19. Install the spark plug. Refer to Spark Plug Replacement .
20. Install the distributor. Refer to Distributor Replacement .
21. Install the upper intake. Refer to Upper Intake Manifold Replacement .



22. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body.

Tighten
Tighten the accelerator control cable bracket nuts and studs to 12 N·m (106 lb in).




23. Install the water pump inlet hose to the intake manifold.
24. Install the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .
25. Install the radiator inlet hose to the water outlet. Refer to Radiator Inlet Hose Replacement .



26. Connect the following electrical connectors:

•	The fuel meter body assembly connector (1)

•	The evaporative emission (EVAP) canister purge solenoid valve (2)

•	The manifold absolute pressure (MAP) sensor (3)

•	The A/C high pressure switch (4), if equipped




27. Connect the following electrical connectors:

•	The A/C compressor clutch (1), if equipped

•	The EGR valve (2)

•	The ECT sensor (3)

28. Install the ground wire (4) and the nut to the water outlet stud.

Tighten
Tighten the ground wire nut to 10 N·m (88 lb in).

29. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement .
30. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to Accelerator Control Cable Replacement .
31. Refill the cooling system. Refer to Cooling System Draining and Filling .



32. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
33. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
34. Install the engine cover. Refer to Engine Cover Replacement .