Intake Manifold

Intake Manifold

REMOVAL & INSTALLATION

2.2L Engines

Fig. 1: Exploded view of the intake manifold assembly-2.2L engine

Before servicing the vehicle, refer to the precautions in the beginning of this section.
Release the fuel system pressure.
Remove or disconnect the following:
- Negative battery cable
- Engine cover, if necessary
Drain the cooling system into a suitable container.
- Mass Air Flow (MAF) sensor electrical connector for 1998-99 vehicles, except California vehicles
- Intake Air Temperature (IAT) sensor electrical connector for 1999 California vehicles
- Clamp that connects the air intake duct to the air intake chamber
- Air cleaner cover clips
- Blow-by hose from the air intake duct
- Air intake duct and air cleaner cover as an assembly
- Air cleaner element
Loosen the clamp that connects the air intake chamber to the throttle body
- Air hoses and air intake chamber
- Accelerator cable and cruise control cable, if equipped
- Vacuum hoses from the pressure sources switching solenoid valve
- Resonator chamber on 1999 California models and all 2000-01 models
- Power steering pump drive belt cover(s) and belt
- Power steering pipe brackets from the right side of the intake manifold
- Power steering pump from bracket, then position on the right side wheel apron; do not disconnect the fluid lines
- Fuel pipe protector, if equipped
- Spark plug wires and electrical connector from ignition coil
- Positive Crankcase Ventilation (PCV) hose and pressure regulator vacuum hose from intake manifold
- Coolant hoses from the throttle body
- Engine coolant hose and air by-pass hose from the idle air control solenoid valve
- Brake booster hose
- Cruise control vacuum hose, if equipped
- Exhaust Gas Recirculation (EGR) pipe, on 2.2L engines with automatic transaxle
- Canister hoses from the pipes
- Engine harness connectors from bulkhead harness connectors, then remove from bracket
- Engine Coolant Temperature (ECT) sensor connector and thermometer connector, if equipped
- Knock sensor connector
- Crankshaft Position (CKP) and Camshaft Position (CMP) sensor connectors
- Oil pressure switch connector
- Fuel supply lines
- Intake manifold bolts
- Intake manifold and discard the gaskets
Clean all gasket material from both mating surfaces.
To install:
Use a straightedge and a feeler gauge to inspect the intake manifold for flatness. Distortion should not exceed 0.020 in. (0.5mm).
Install or connect the following:
- Intake manifold to the engine. Tighten the retaining bolts to 16.7-19.5 ft. lbs. (23-27 Nm).
- Fuel lines
- Oil pressure switch electrical connector
- CKP and CMP sensors
- Knock sensor
- ECT sensor and thermometer connectors
- Engine harness connector to the bracket and bulkhead
- Canister hoses, if disconnected
- Install the EGR pipe, if removed
- Cruise control vacuum hose, if equipped
- Brake booster vacuum hose
- Air bypass hose to the FICD solenoid valve
- PCV valve hose to the manifold
- Coolant hoses to throttle body
- Electrical connector and spark plug wires to ignition coil
- Fuel pipe protector, if equipped
- Power steering pump to bracket
- Power steering pump bolts and tighten to 13-16.6 ft. lbs. (17.6-22.6 Nm)
- Power steering brackets to the right side of the intake manifold
- Power steering pump belt and adjust the belt
- Power steering pump belt cover
- Vacuum hoses to pressure sources switching solenoid valve
- Accelerator cable and cruise control cable, if equipped
- Air intake chamber and hoses
- Air cleaner element, and the upper cover and duct as a unit
- MAF sensor electrical connector
- Engine cover, if equipped
- Negative battery cable
Fill the cooling system.
Start the engine and allow it to reach operating temperature. Check for leaks and test drive the vehicle.

2.5L Engine

Before servicing the vehicle, refer to the precautions in the beginning of this section.
Disconnect the negative battery cable.
Drain the cooling system into a suitable container.
Remove or disconnect the following:
- Mass Air Flow (MAF) sensor connector, if necessary
- Air intake duct, air cleaner upper cover and the air cleaner element
Properly release the fuel pressure.
Remove or disconnect the following:
- Accelerator cable and the cruise control cable, if equipped
- Resonator chamber, if equipped
- V-belt cover(s)
Loosen the lock bolt and slider bolt, then remove the power steering belt
Remove or disconnect the following:
- Power steering pipe bracket-to-manifold bolts
- Bolts holding the power steering pump to the bracket
- Connector from the power steering pump switch, if equipped
- Power steering pump, and place on the right side wheel apron. Do NOT disconnect the fluid lines.
- Spark plug wires from the ignition coil and igniter, on 1998-99 vehicles, or from the spark plugs, on 2000-01 vehicles
- Positive Crankcase Ventilation (PCV) hose and vacuum hose from the intake manifold
- Engine coolant hoses from the throttle body
- Engine coolant hose and air bypass hose from the idle air control solenoid valve, on 1998 vehicles
- Brake booster hose
- EGR pipe, on 1998 vehicles
- Engine harness bracket from transmission housing, on 1998 vehicles
- Air cleaner case stay (right side) and engine harness bracket, on 1999-01 vehicles
- Engine harness connectors form the bulkhead harness connectors
- Engine Coolant Temperature (ECT) sensor connector
- Knock sensor, Camshaft Position (CMP) sensor and Crankshaft Position (CKP) sensor electrical connectors
- Oil pressure switch
- Fuel hoses from the fuel pipes
- Intake manifold mounting bolts
- Intake manifold and discard the gaskets
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. 2: Exploded view of the intake manifold and related components-2.5L engine
Install or connect the following:
- New gaskets
- Intake manifold to the engine. Tighten the mounting bolts to 16.7-19.5 ft. lbs. (23-27 Nm).
- Fuel hoses to the fuel pipes, be sure to secure the hoses with new clamps
- Knock sensor, CMP sensor, CKP sensor, oil pressure switch and ECT sensor wiring
- Engine harness bracket and engine harness connectors to bulkhead connectors
- EGR pipe, if removed
- Brake booster hose
- Engine coolant hose and air bypass hose to idle air control solenoid valve, if removed
- Engine coolant hoses to the throttle body
- PCV hoses to intake manifold
- Spark plug wires to ignition coil or plugs, as applicable
- Power steering pump to bracket. Tighten the bolts to 13-16.6 ft. lbs. (17.6-22.6 Nm).
- Power steering pipe brackets on right side of the intake manifold
- Bolt, which installs the power steering pump stiffener on the engine block, to 14.4-17.3 ft. lbs. (20-24 Nm)
- Power steering pump belt and adjust the belt as necessary
- V-belt cover(s)
- Resonator chamber, if equipped
- Accelerator cable and the cruise control cable, if equipped
- Air cleaner assembly
- MAF sensor connector, if disconnected
Connect the negative battery cable and refill the cooling system. Start the engine, and bleed the cooling system. Check for leaks.