Intake Manifold Replacement Lower

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 .
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.



4. Remove the following coolant hoses:
5. Upper radiator hose. Refer to Radiator Hose Replacement .
6. Both heater hoses. Refer to Heater Hoses Replacement in Engine Cooling.
7. Water pump inlet hose. Refer to Heater Water Bypass Valve Replacement in Engine Cooling.
8. Disconnect all electrical connectors and secure out of the way.
9. Remove the distributor. Refer to Distributor Replacement in Engine Electrical.
10. Use a twisting motion to remove the vacuum brake booster hose, if equipped.
11. Disconnect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement in Engine Controls.
12. Remove the drive belt. Refer to Drive Belt Replacement .

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

13. Remove the air conditioning (A/C) compressor, if equipped, and set the A/C compressor aside. Refer to Air Conditioning Compressor Replacement .



14. Remove the PCV valve.
15. Disconnect the exhaust gas recirculation (EGR) pipe from the bracket and the front of the intake manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement in Engine Controls.
16. Disconnect the fuel pipes from the rear of the intake manifold. Refer to Fuel Hose/Pipes Assembly Replacement in Engine Controls.
17. Disconnect the electrical connector from the power steering pump.



18. Remove the power steering bracket using the following procedure:

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

•	Remove the nut, then the bolts.

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

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

19. Disconnect the wiring bracket from the rear of the right cylinder head.
20. Remove the valve rocker arm covers. Refer to Valve Rocker Arm Cover Replacement .
21. Remove the intake manifold. Refer to Intake Manifold Removal .
22. 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 covers Refer to Valve Rocker Arm Cover Installation (Right) and Valve Rocker Arm Cover Installation (Left) .




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 bracket using the following procedure:

•	Install the power steering 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.

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

•	Install the power steering pump. Refer to Power Steering Pump Replacement in Power 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 Assembly Replacement in Engine Controls.

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




4. Install the PCV valve.
5. Connect the exhaust gas recirculation (EGR) pipe to the bracket and the front of the intake manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement in Engine Controls.
6. Use a twisting motion to install the vacuum brake booster hose, if equipped.
7. Install AIR check valve (crossover) pipe, if equiped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement in Engine Controls.



8. Install the air conditioning (A/C) compressor onto the power steering bracket.
9. Install the A/C compressor bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

10. Install the drive belt. Refer to Drive Belt Replacement .
11. Connect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement in Engine Controls.
12. Install the distributor. Refer to Distributor Replacement .
13. Connect all electrical connectors.



14. 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.

•	Water pump inlet. Refer to Heater Water Bypass Valve Replacement in Engine Cooling.

•	Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.

•	Fill the cooling system with coolant. Refer to Cooling System Draining and Filling .

•	Connect the battery negative cable. Refer to Battery Cable in Engine Electrical.

Intake Manifold Replacement Upper

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 vacuum brake booster hose, if equipped.
5. Disconnect the accelerator control and cruise control cables (if equipped). Refer to Accelerator Controls Cable Replacement in Engine Controls.
6. Remove the accelerator control cable bracket and set it aside.
7. Remove the following electrical connectors:

•	The SCPI injector harness connector

•	The EVAP canister purge solenoid valve

•	The ignition coil

•	The ignition control module (ICM)

•	The generator

•	The idle air control (IAC) motor

•	The throttle position (TP) sensor

•	The oxygen (O²) sensor

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT) sensor

•	The engine oil pressure sensor

•	Disconnect the fuel pipes from the fuel pipes. Refer to Fuel Hose/Pipes Assembly Replacement in Engine Controls.

•	Remove the AIR check valve (crossover) pipe, if equiped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement in Engine Controls.

•	Remove the distributor cap and reposition the distributor cap out of the way. Refer to Distributor Replacement in Engine Electrical.




8. Remove the PCV valve hose assembly.



9. Remove the engine wiring harness bracket from the manifold.
10. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.



11. Remove the studs holding the upper intake manifold to the lower intake manifold.
12. Remove the lower intake manifold. Refer to Intake Manifold Disassemble .
13. Clean all the surfaces. Refer to Intake Manifold Clean and Inspect .

1. Install the lower intake manifold. Refer to Intake Manifold Assemble .
2. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.




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 engine wiring harness bracket to the upper intake manifold.

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




4. Install the PCV valve hose assembly.
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 Assembly Replacement in Engine Controls.
7. Install the AIR check valve (crossover) pipe, if so equiped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement in Engine Controls.
8. Connect the electrical connectors.
9. Install the accelerator control cable bracket.
10. Connect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement in Engine Controls.



11. Install the vacuum brake booster hose, if equipped.
12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
13. Connect the battery negative cable. Refer to Battery Cable in Engine Electrical.