Lower Intake Manifold
REMOVAL - LOWER1. Disconnect negative cable from battery.
2. Disconnect connector from inlet air temperature sensor.
3. Disconnect air intake tube at throttle body and remove upper air cleaner housing.
4. Disconnect connector from throttle position sensor (TPS).
5. Disconnect connector from idle air control (IAC) motor.
6. Disconnect connector from MAP sensor.
7. Remove vacuum lines for purge solenoid and PCV valve at intake manifold.
8. Remove vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum reservoir (if equipped) at intake manifold fittings.
9. Disconnect throttle, speed control (if equipped), and transaxle control (if equipped) and cables from throttle lever and bracket.
10. Perform fuel system pressure release procedure before attempting any repairs.
11. Disconnect fuel line.
12. Disconnect coolant temperature sensor/fuel injector wire harness connector.
13. Disconnect fuel injector harness.
14. Remove intake manifold to cylinder head fasteners.
15. Remove the manifold from engine.
CAUTION: Cover intake manifold openings to prevent foreign material from entering engine.
16. Inspect the manifold.
INSPECTION
1. Check manifold surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 inch per foot) of manifold length.
2. Inspect manifold for cracks or distortion. Replace manifold if necessary.
INSTALLATION - LOWER
If the following items were removed, install and torque to specifications:
^ Fuel rail bolts - 22 Nm (200 inch lbs.)
^ Coolant outlet connector bolts - 28 Nm (250 inch lbs.)
^ Coolant temperature sensor - 7 Nm (60 inch lbs.)
1. Position a new gasket on cylinder head and install lower manifold.
2. Install and tighten intake manifold fasteners to 28 Nm (250 inch lbs.) in the sequence shown in (Fig. 99). Repeat procedure until all bolts are at specified torque.
3. Install lower intake manifold support bracket bolts.
^ Bolts to intake 28 Nm (250 inch lbs.)
^ Bolt to engine block 54 Nm (40 ft. lbs.)
4. Connect the fuel line.
5. Connect coolant temperature sensor/fuel injector wiring harness electrical connector.
6. Install the radiator upper and heater supply hoses.
7. Install the upper intake manifold.
8. Fill the cooling system.