Intake Manifold

REMOVAL & INSTALLATION

1999-02

CAUTION
The fuel injection system remains under pressure after the engine has been turned

OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Properly relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   • Fuel filler cap
   • Negative battery cable
   • Air intake duct, air cleaner upper cover and the air cleaner element
   • Accelerator cable and the cruise control cable, if equipped
   • Resonator chamber
   • V-belt covers
   • Power steering V-belt
   • Power steering hose brackets from intake manifold
   • Power steering pump and seat aside, do not disconnect hoses
   • Spark plug wires
   • Positive Crankcase Ventilation (PCV) hose and vacuum hose from intake manifold
   • Engine coolant hoses from throttle body
   • Brake booster hose
   • Air cleaner case stay and engine harness bracket
   • Coolant temperature sensor connector
   • Knock Sensor (KS) connector
   • Crankshaft Position (CMP) sensor
   • Oil pressure switch
   • Camshaft Position (CKP) sensor
   • Fuel hoses from fuel pipes
   • Intake manifold
   • Throttle Position (TP) sensor
   • Ground cable from the intake manifold
   • Ignition coil and igniter assembly
   • Intake Air Temperature (IAT) and pressure sensor
   • Idle Air Control (IAC) solenoid valve
   • Throttle Position (TP) sensor and air control solenoid
   • Air bypass from throttle body
   • Throttle body from the intake manifold and discard the gasket
   • Air bypass hose from air assist solenoid
   • Air assist injector solenoid valve
   • Pressure regulator vacuum hose from intake manifold
   • Fuel injectors
   • Purge control solenoid valve
   • Air bypass hose from purge control solenoid valve
   • Harness bands
   • Engine harness from intake manifold
   • Purge control solenoid valve
   • Injector pipe
   • Fuel pipes from the intake manifold
   • Fuel injectors and securing clips
   • Air bypass hoses from the manifold
5. Loosen the right and left fuel hose to injector clamps.
6. Remove or disconnect the following:
   • Left and right side fuel pipes
   • Fuel injector pipe
   • Fuel pipe assembly and pressure regulator

   NOTE: The intake manifold sits on pins that protrude from the cylinder heads. Be sure the pins remain in the cylinder heads.

   To install:

   Fig. 1: Exploded view of the intake manifold

7. Install or connect the following:
   • Fuel pipe assembly and pressure regulator
   • Right side fuel pipes, tighten clamps
   • Fuel injector pipe
   • Left side fuel pipes, tighten clamps
   • Air bypass hoses to the manifold
   • Fuel injectors and securing clips
   • Fuel pipes to the intake manifold. Torque the bolts to 2.5 ft. lbs. (3.4 Nm).
   • Injector pipe. Torque the bolts to 3.6 ft. lbs. (4.9 Nm).
   • Purge control solenoid valve
   • Air bypass hose from purge control solenoid valve
   • Engine harness to intake manifold and harness bands
   • Pressure regulator vacuum hose to intake manifold
   • Air assist injector solenoid valve
   • Air bypass hose to air assist solenoid
   • Throttle body to the intake manifold using new gaskets. Torque the retaining bolts to 16 ft. lbs. (22 Nm).
   • TP sensor and air control solenoid
   • Air bypass hoses to the manifold
   • IAC solenoid valve to the intake manifold using a new gasket. Tighten the retaining bolts to 60 inch lbs. (7 Nm).
   • IAT and pressure sensor use new O-ring. Torque the bolts to 1.4 ft. lbs. (2.0 Nm).
   • Ignition coil and ignitor assembly
   • Ground cable from the intake manifold
   • Air cleaner case stay and engine harness bracket
   • Brake booster hose
   • Engine coolant hoses to the throttle body.
   • PCV hose and vacuum hose to intake manifold
   • Spark plug wires
   • Power steering pump to intake manifold. Torque the bolts to 15 ft. lbs. (20 Nm).
   • Power steering hose brackets to the right side of the intake manifold
   • Power steering V-belt
   • V-belt covers
   • Resornator chamber. Torque the bolts to 25 ft. lbs. (33 Nm).
   • Accelerator cable and the cruise control cable
   • Air cleaner assembly
   • Negative battery cable
8. Refill the cooling system.
9. Start the engine, and bleed the cooling system.
10. Check for leaks.