Chrysler Colt/Vista 1990-1993 Repair Information

Intake Manifold

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REMOVAL & INSTALLATION



See Figures 1 through 8

The intake manifold is made from cast aluminum and should not he removed until the engine is cold.

  1. Remove the air cleaner assembly.
  2.  
  3. Release fuel system pressure and disconnect the fuel line and the EGR lines (models equipped with EGR) and tag and disconnect all vacuum hoses.
  4.  
  5. Disconnect the throttle positioner and fuel cut-off solenoid wires.
  6.  
  7. Disconnect the throttle linkage. On automatic transmission cars disconnect the shift cable linkage.
  8.  



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Fig. Fig. 1: 1990 1.5L engine. Remove these parts, in the order shown, to prepare for intake manifold removal. When installing, reverse the removal order



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Fig. Fig. 2: 1.6L engine. Remove these parts, in the order shown, to prepare for intake manifold removal. When installing, reverse the removal order



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Fig. Fig. 3: 1990 1.8L engine. To remove the upper and lower intake manifolds, proceed in the order illustrated. When installing the manifolds, reverse the removal sequence



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Fig. Fig. 4: 2.0L engine. To remove the upper and lower intake manifolds, proceed in the order illustrated. When installing the manifolds, reverse the removal sequence

  1. On the 1.6L engine, remove the fuel pump and the thermostat housing. Also, disconnect the power brake booster vacuum line.
  2.  
  3. Drain the engine coolant.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.



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Fig. Fig. 5: 1991-92 1.5L engine. Remove these parts, in the order shown, to prepare for intake manifold removal. When installing, reverse the removal order



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Fig. Fig. 6: 1992-93 1.8L engine. Remove these parts, in the order shown, to prepare for intake manifold removal. When installing, reverse the removal order

  1. Remove the heater and water outlet hoses, disconnect the water temperature sending unit. Disconnect the oxygen sensor connector, power transistor connector, ISC connector, ignition coil connector, etc., and the distributor.
  2.  



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Fig. Fig. 7: 1992-93 1.8L engine. To remove the intake manifold, proceed in the order illustrated. When installing the manifold, reverse the removal sequence



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Fig. Fig. 8: 2.4L engine. To remove the upper and lower intake manifolds, proceed in the order illustrated. When installing the manifolds, reverse the removal sequence

  1. Remove the mounting nuts that hold the manifold to the cylinder head. Remove the intake manifold lower and upper sections with injector assembly as a unit.
  2.  
  3. Clean all mounting surfaces. Before installing the manifold, coat both sides with a gasket sealer.
  4.  
  5. Install all components and the intake manifold in reverse order of removal. Torque values follow: manifold to head bolts 11-14 ft. lbs. (15-20 Nm); upper to lower manifold 11-14 ft. lbs. (15-20 Nm); fuel delivery manifold 7-9 ft. lbs. (10-12 Nm); throttle body 11-16 ft. lbs. (14-21 Nm) on DOHC, 2.0L and 2.4L; 7-9 ft. lbs. (10-12 Nm) on 1.5L.
  6.  

If the engine is equipped with the jet air system, take care not to get any sealer into the jet air intake passage.

 
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