Intake Manifold Replacement - Lower

Removal Procedure





1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement. Remove the engine cover. Refer to Engine Cover Replacement.
5. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
6. Remove the following coolant hoses:
6.1. Upper radiator hose. Refer to Radiator Hose Replacement in Cooling System.
6.2. Inlet heater hose. Refer to Heater Hoses Replacement in Heating and Air Conditioning- non AC equipped.
6.3. Outlet heater hose. Refer to Heater Hoses Replacement in Heating and Air Conditioning-non AC equipped.
6.4. Coolant by-pass hose. Refer to Coolant Bypass Hose Replacement in Cooling System.
7. Disconnect the following electrical connectors.
- SCPI injector electrical connector. Refer to Fuel Meter Body Assembly Replacement.
- Manifold Absolute Pressure (MAP) sensor. Refer to Manifold Absolute Pressure (MAP) Sensor Replacement.
- EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
- Idle Air Control (IAC) motor. Refer to Idle Air Control (IAC) Valve Replacement.
- Throttle Position (TP) sensor. Refer to Throttle Position (TP) Sensor Replacement.
- Exhaust Gas Recirculation (EGR) valve. Refer to Exhaust Gas Recirculation (EGR) Valve Replacement.
- Engine Coolant Temperature (ECT) sensor. Refer to Engine Coolant Temperature (ECT) Sensor Replacement.
8. Remove AIR bypass hose assembly, if so equipped. Refer to Sec Air Injection Check Valve/Pipe Replacement.
9. Use a twisting motion in order to remove the brake booster vacuum hose, if equipped. Refer to Vacuum Brake Booster Replacement.
10. Remove the distributor from the engine. Refer to Distributor Replacement.
11. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement Engine Compartment.
12. Remove the accelerator control cable and the cruise control cables, if equipped, from the throttle shaft. Refer to Accelerator Controls Cable Replacement.
13. Remove the accelerator control cable bracket from the throttle body and the lower intake manifold.
14. Remove the ignition coil and ICM bracket. Refer to Ignition Coil and ICM Replacement.
15. Remove the EGR pipe from the intake manifold. Refer to Exhaust Gas Recirculation (EGR) Pipe Replacement.





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

16. Remove the air conditioning (A/C) compressor, if equipped, and set aside. Refer to Compressor Replacement in Heating and Air Conditioning.
17. Remove the power steering pulley from the power steering pump. Refer to Power Steering Pulley Replacement (Gasoline) or Power Steering Pulley Replacement (Diesel) in Steering and Suspension.
18. Remove the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement (Left) or Accessory Mounting Brackets Replacement (Right).
19. Remove the left side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Right) or Valve Rocker Arm Cover Replacement (Left).
20. Remove the right side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Right) or Valve Rocker Arm Cover Replacement (Left).





21. Remove the lower intake manifold from the engine.
22. Clean all sealing surfaces.


Installation Procedure





1. Install the lower intake manifold to the engine. Refer to Intake Manifold Installation.
2. Install the left side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Right) or Valve Rocker Arm Cover Replacement (Left).
3. Install the right side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Right) or Valve Rocker Arm Cover Replacement (Left).
4. Install the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement (Left) or Accessory Mounting Brackets Replacement (Right).
5. Install the air conditioning (A/C) compressor, if equipped. Refer to Compressor Replacement in Heating and Air Conditioning.





6. Connect the Exhaust Gas Recirculation (EGR) pipe to the bracket and the front of the intake manifold. Refer to Exhaust Gas Recirculation (EGR) Pipe Replacement.
7. Install the ignition coil and the ICM bracket. Refer to Ignition Coil and ICM Replacement.
8. Install AIR bypass hose assembly, if so equipped.





9. Install the accelerator control cable bracket to the throttle body and the lower intake manifold. Refer to Accelerator Controls Cable Replacement.
10. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Controls Cable Replacement.
11. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
12. Install the distributor to the engine. Refer to Distributor Replacement.
13. Install the PCV tube at intake manifold using a twisting motion in order to lock.
14. Install the vacuum brake booster hose, if equipped.
15. Connect the following electrical connectors:
- SCPI injector electrical connector. Refer to Fuel Meter Body Assembly Replacement.
- Manifold Absolute Pressure (MAP) sensor. Refer to Manifold Absolute Pressure (MAP) Sensor Replacement.
- EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
- Idle Air Control (IAC) motor. Refer to Idle Air Control (IAC) Valve Replacement.
- Throttle Position (TP) sensor. Refer to Throttle Position (TP) Sensor Replacement.
- Exhaust Gas Recirculation (EGR) valve. Refer to Exhaust Gas Recirculation (EGR) Valve Replacement.
- Engine Coolant Temperature (ECT) sensor. Refer to Engine Coolant Temperature (ECT) Sensor Replacement.
16. Install the AIR bypass hose assembly, if so equipped. Refer to Sec Air Injection Check Valve/Pipe Replacement.
17. Install the brake booster vacuum hose, if so equipped. Refer to Vacuum Brake Booster Replacement.
18. Install the upper radiator hose. Refer to Radiator Hose Replacement in Cooling System.
19. Install the inlet heater hose. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
20. Install the outlet heater hose. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
21. Install the coolant bypass hose. Refer to Coolant Bypass Hose Replacement in Cooling System.
22. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Cooling System.
23. Install the engine cover. Refer to Engine Cover Replacement Engine Cover.
24. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
25. Fill the engine with coolant. Refer to Draining and Filling Cooling System in Cooling System.
26. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.