Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Intake and Exhaust Manifolds

Print

REMOVAL & INSTALLATION



Of all the 4-cylinder engines covered by this information, only two (the 2.2L Turbo III and 2.6L) have exhaust and intake manifolds which are totally independent from each other. All other engines share the intake/exhaust manifold gasket-some even share mounting bolts-therefore both manifolds must be removed to replace the gasket, which should be replaced every time one of the manifolds is removed from the cylinder head.


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by 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.

2.2L and 2.5L Non-Turbocharged Except Premier Engines

See Figures 1 through 7

Click image to see an enlarged view

Fig. Fig. 1: To remove the intake/exhaust manifolds, first remove the air cleaner assembly ...



Click image to see an enlarged view

Fig. Fig. 2: ... then loosen the intake manifold attaching bolts



Click image to see an enlarged view

Fig. Fig. 3: After removing the throttle body, remove the attaching bolts and manifold



Click image to see an enlarged view

Fig. Fig. 4: Detach the front exhaust pipe from the exhaust manifold ...



Click image to see an enlarged view

Fig. Fig. 5: ... then remove the oxygen sensor from the exhaust manifold



Click image to see an enlarged view

Fig. Fig. 6: Remove the exhaust manifold-to-cylinder head attaching bolts ...



Click image to see an enlarged view

Fig. Fig. 7: ... then remove the exhaust manifold from the cylinder head

1981-86 MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system, as described in Routine Maintenance .
  4.  
  5. Remove the air cleaner and hoses.
  6.  
  7. If the engine is fuel injected, depressurize the fuel system, as described in Fuel System . Remove all wiring and any hoses connected to the carburetor or injection throttle body and the manifold.
  8.  
  9. Disconnect the accelerator linkage.
  10.  
  11. Loosen the power steering pump mounting bolts and remove the belt. Disconnect the power brake vacuum hose at the manifold.
  12.  
  13. On Canadian cars, remove the coupling hose (connecting the diverter valve and the exhaust manifold air injection tube).
  14.  
  15. Disconnect the water hose from the water crossover.
  16.  
  17. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  18.  
  19. Disconnect the exhaust system from the exhaust manifold.
  20.  
  21. Remove the power steering pump, leaving the lines connected, and hang it to one side so the hoses are not stressed.
  22.  
  23. Remove the intake manifold support bracket.
  24.  
  25. Remove the intake manifold-to-head bolts.
  26.  
  27. Lower the vehicle and remove the intake manifold from the cylinder head.
  28.  
  29. Remove the exhaust manifold retaining nuts and remove the exhaust manifold.
  30.  

To install:
  1. Clean all gasket surfaces and reposition the intake and exhaust manifolds using new gaskets. A composition gasket must be installed without any sealant, whereas a steel gasket must be coated with a sealer such as Chrysler Part No. 3419115 or equivalent.
  2.  
  3. Situate the exhaust manifold in position and install the retaining nuts finger-tight. Set the intake manifold into position and install all accessible bolts. Raise the car and support it securely on jackstands.
  4.  
  5. Install all the manifold-to-head bolts finger-tight. Install the intake manifold support bracket. Install the power steering pump, bolting it into position with the mounting bolts just finger-tight.
  6.  
  7. Connect the exhaust pipe at the manifold using a new seal, then tighten the bolts and nuts to 21 ft. lbs. (28 Nm).
  8.  
  9. Lower the car and tighten the manifold nuts and bolts in three stages, starting at the center and progressing outward, to 17 ft. lbs. (23 Nm).
  10.  
  11. Connect the power brake vacuum hose to the manifold. Connect the water hose to the water crossover.
  12.  
  13. On Canadian cars, install the coupling hose (connecting the diverter valve and the exhaust manifold air injection tube).
  14.  
  15. Install the power steering pump belt and adjust the belt tension, as described in Routine Maintenance .
  16.  
  17. Connect the accelerator linkage, then install the air cleaner and hoses.
  18.  
  19. Install all wiring and hoses disconnected from the carburetor or throttle body and the manifold.
  20.  
  21. Refill the cooling system, reconnect the battery, start the engine and run it to check for leaks.
  22.  
  23. Refill the cooling system after the engine has reached operating temperature (air has been bled out) and it has cooled off again.
  24.  

1987-95 ELECTRONIC FUEL INJECTED (NON-FLEX FUEL) MODELS

See Figures 8 and 9

Click image to see an enlarged view

Fig. Fig. 8: Exploded view of the fresh air duct and throttle body on the non-turbocharged 2.2L and 2.5L engines



Click image to see an enlarged view

Fig. Fig. 9: Location of the intake manifold and exhaust manifold mounting bolts

On some vehicles, some of the manifold attaching bolts are not accessible or too heavily sealed from the factory and cannot be removed on the vehicle. Head removal would be necessary in these situations.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure, as described in Fuel System .
  4.  
  5. Drain the cooling system. For more details, refer to Routine Maintenance .
  6.  
  7. Remove the air cleaner and disconnect all vacuum lines, electrical wiring and fuel lines from the throttle body.
  8.  
  9. Disconnect the throttle linkage.
  10.  
  11. Loosen the power steering pump and remove the drive belt.
  12.  
  13. Remove the power brake vacuum hose from the intake manifold.
  14.  
  15. Remove the water hoses from the water crossover.
  16.  
  17. Apply the parking brakes, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  18.  
  19. Disconnect the exhaust pipe from the exhaust manifold.
  20.  
  21. Remove the power steering pump from its mounting bracket and set it aside without disconnecting the fluid hoses.
  22.  
  23. Remove the intake manifold support bracket, if equipped.
  24.  
  25. Remove the EGR tube, if equipped.
  26.  
  27. Remove the intake manifold bolts.
  28.  
  29. Lower the vehicle and remove the intake manifold.
  30.  
  31. Remove the exhaust manifold retaining nuts, then remove the exhaust manifold.
  32.  

To install:
  1. Discard the gaskets and clean all gasket surfaces on both manifolds and on the cylinder head.
  2.  
  3. Test the gasket surfaces of the manifolds for flatness with a straightedge. Surface warpage must not exceed 0.006 in. (0.15mm) per foot (30cm) of manifold length.
  4.  
  5. Inspect the manifolds for cracks and distortion; replace the manifolds if any such damage is evident.
  6.  
  7. Install a new combination manifold gasket. Coat a steel gasket lightly with Chrysler Gasket Sealer, or equivalent, on the manifold side. DO NOT coat composition gaskets with any sealer.
  8.  
  9. Install the exhaust manifold assembly. Starting from the middle and working outwards, install the mounting nuts and tighten to 17 ft. lbs. (23 Nm). Install the heat cowl to the exhaust manifold.
  10.  
  11. Install the intake manifold. Starting from the middle and working outward, tighten the bolts to 17 ft. lbs. (23 Nm.).
  12.  
  13. Raise and safely support the front of the vehicle on jackstands.
  14.  
  15. Connect the exhaust system to the exhaust manifold, as described later in this section.
  16.  
  17. Install the EGR tube, if removed.
  18.  
  19. Install the intake manifold support bracket, if equipped.
  20.  
  21. Install the power steering pump.
  22.  
  23. Lower the vehicle and remove the wheel blocks.
  24.  
  25. Install the water hoses to the water crossover.
  26.  
  27. Install the power brake vacuum hose to the intake manifold.
  28.  
  29. Connect the throttle linkage, as described in Fuel System .
  30.  
  31. Install all vacuum lines, electrical wiring and fuel lines to the throttle body.
  32.  
  33. Install the air cleaner assembly.
  34.  
  35. Refill the cooling system.
  36.  
  37. Connect the negative battery cable and check for leaks.
  38.  

1993-95 FLEXIBLE FUEL ELECTRONIC FUEL INJECTED ENGINES

See Figures 10 through 13

Click image to see an enlarged view

Fig. Fig. 10: Location of the pressure test port on the fuel rail for relieving the fuel system pressure



Click image to see an enlarged view

Fig. Fig. 11: Location of the Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor-Flex Fuel engines



Click image to see an enlarged view

Fig. Fig. 12: Detach the connections shown before removing the intake and exhaust manifolds



Click image to see an enlarged view

Fig. Fig. 13: Location of the intake and exhaust manifold retaining bolts for the Flex Fuel engines


CAUTION
Before servicing any flexible fuel system components, refer to the warnings in Routine Maintenance . Methanol is more toxic than gasoline and requires extreme care when handling.

  1. Disconnect the negative battery cable.
  2.  


CAUTION
Release fuel system pressure before servicing any fuel system components. Wear methanol resistant gloves and eye protection while servicing the fuel system.

  1. Release the fuel system pressure, as described in Fuel System .
  2.  
  3. Remove the air cleaner hose from the throttle body.
  4.  
  5. Remove the accelerator and cruise control cables, if equipped.
  6.  
  7. Disengage the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors.
  8.  
  9. Disconnect the fuel injectors' wiring connector.
  10.  
  11. Remove the fuel supply and return lines from the fuel tube assembly quick-disconnect from the frame rail, as described in Fuel System . Open the fuel tube clip around the fuel tubes.
  12.  


CAUTION
Have shop rags handy to catch any residual fuel leakage when the fuel lines are detached.

  1. Detach the fuel pressure regulator vacuum hose from the regulator.
  2.  
  3. Remove the PCV vacuum harness, brake booster, and vacuum vapor harness from the intake manifold.
  4.  
  5. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  6.  
  7. Disconnect the exhaust system from the exhaust manifold.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the 8 intake manifold bolts and washers, then remove the intake manifold from the cylinder head.
  12.  
  13. Disconnect the exhaust pipe from the exhaust manifold articulate joint.
  14.  
  15. Disengage the heated oxygen sensor electrical connection.
  16.  
  17. Remove the 8 exhaust manifold retaining nuts and remove the exhaust manifold from the cylinder head.
  18.  

To install:
  1. Discard the gasket and clean all gasket surfaces on the manifolds and cylinder head.
  2.  
  3. Test the gasket surfaces for flatness with a straightedge. the surface must be flat within 0.006 in. (0.15mm) per foot (30cm) of manifold length.
  4.  
  5. Inspect the manifolds for cracks or distortion.
  6.  
  7. Install a new two-sided Grafoil® or equivalent intake/exhaust manifold gasket. DO NOT apply sealer.
  8.  
  9. Set the exhaust manifold in position on the cylinder head, then install and tighten the retaining nuts, starting at the center and progressing outward in both directions. Tighten the nuts to 17 ft. lbs. (23 Nm).
  10.  
  11. Position the intake manifold on the cylinder head, then install and tighten the 8 retaining bolts, starting at the center and progressing outward in both directions. Tighten the bolts to 17 ft. lbs. (23 Nm).
  12.  
  13. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  14.  
  15. Attach the exhaust system to the exhaust manifold, as described later in this section.
  16.  
  17. Lower the vehicle and remove the wheel blocks.
  18.  
  19. Install the PCV vacuum harness and vacuum vapor harness.
  20.  
  21. Attach the vacuum hose to the fuel pressure regulator.
  22.  
  23. Attach the fuel injectors' wiring connector.
  24.  
  25. Close the fuel tube clip around the fuel tubes and install the fastener.
  26.  
  27. Lubricate the ends of the chassis fuel tubes with 30W oil. Connect the fuel supply and return hoses to the chassis fuel tube assembly; pull back on the quick-disconnect fittings to ensure complete engagement. For more information on fuel tube quick-disconnect fittings, refer to Fuel System .
  28.  
  29. Attach the AIS motor and the TPS wiring connectors.
  30.  
  31. Connect the accelerator and, if equipped, cruise control cables to the throttle body.
  32.  
  33. Install the brake booster vacuum supply hoses.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Install the air cleaner hose to the throttle body assembly.
  38.  
  39. Start the engine and check for leaks.
  40.  

2.2L Turbo I and Turbo II Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Remove the air cleaner assembly and intake manifold upper plenum-to-cylinder head support bracket.
  6.  
  7. Separate the throttle body assembly from the intake manifold. Detach the EGR tube from the valve.
  8.  
  9. Disengage the PCV, Manifold Absolute Pressure (MAP) and brake booster vacuum supply hoses. Disengage the charge temperature sensor electrical connector.
  10.  
  11. Remove the starter motor. For more information, refer to Engine Electrical .
  12.  
  13. From under the vehicle, remove the 7 bolts to separate the upper intake manifold plenum from the lower intake manifold runner.
  14.  
  15. From above the engine, remove the upper plenum and plenum runner gasket. Cover the lower intake manifold runner opening with a clean shop rag to prevent any debris from falling into the engine.
  16.  


WARNING
Do not allow any debris to enter the runners.

  1. Remove the cowl mounted heat shield and fuel rail, as described in Fuel System .
  2.  
  3. Remove the turbocharger, as described later in this section.
  4.  
  5. Remove the 8 lower intake manifold bolt and washer assemblies and remove the lower manifold from the cylinder head.
  6.  
  7. Remove the 8 exhaust manifold bolt and washer assemblies and remove the exhaust manifold from the cylinder head.
  8.  

To install:
  1. Discard the gaskets and clean all gasket surfaces on both manifolds and on the cylinder head.
  2.  
  3. Test the gasket surfaces of the manifolds for flatness with a straightedge. Surface warpage must not exceed 0.006 in. (0.15mm) per foot (30cm) of manifold length.
  4.  
  5. Inspect the manifolds for cracks and distortion; replace the manifolds if any such damage is evident.
  6.  
  7. Install a new Grafoil or equivalent combination manifold gasket. DO NOT coat the gasket with sealer.
  8.  
  9. Position the lower intake manifold against the cylinder head and install the mounting bolts. Tighten the mounting bolts by starting at the center and progressing outward in both directions to 17 ft. lbs. (23 Nm).
  10.  
  11. Position the exhaust manifold against the cylinder head and install the mounting bolts. Tighten the mounting bolts by starting at the center and progressing outward in both directions to 17 ft. lbs. (23 Nm).
  12.  
  13. Install the fuel rail. For more information, refer to Fuel System .
  14.  
  15. Install the cowl mounted heat shield.
  16.  
  17. Install a new gasket on the lower intake manifold runner and install the upper manifold plenum. Tighten the plenum-to-lower manifold bolts to 17 ft. lbs. (23 Nm).
  18.  
  19. Install the plenum-to-cylinder head support bracket and tighten the bolts to 40 ft. lbs. (54 Nm).
  20.  
  21. Install the turbocharger, as described later in this section.
  22.  
  23. Install the starter motor. For more information, refer to Engine Electrical .
  24.  
  25. Attach the PCV, Manifold Absolute Pressure (MAP) and brake booster vacuum supply hoses, as well as the charge temperature sensor electrical connector.
  26.  
  27. Install the throttle body assembly to the intake manifold, as described in Fuel System . Install the EGR tube to the valve.
  28.  
  29. Install the air cleaner assembly.
  30.  
  31. Lower the vehicle and remove the wheel blocks.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Start the engine and check for fuel, coolant, oil and vacuum leaks.
  36.  

2.2L Turbo III Engine
INTAKE MANIFOLD

See Figures 14 and 19

Click image to see an enlarged view

Fig. Fig. 14: Exploded view of the air inlet and air cleaner system on 2.2L Turbo III engines



Click image to see an enlarged view

Fig. Fig. 15: Detach the accelerator and cruise control (if equipped) from the throttle body and cable bracket



Click image to see an enlarged view

Fig. Fig. 16: Location of the throttle body mounting fasteners, the Throttle Position Sensor (TPS) and the Automatic Idle Speed (AIS) motor



Click image to see an enlarged view

Fig. Fig. 17: Detach all of the hoses or wires shown from the engine block and cylinder head



Click image to see an enlarged view

Fig. Fig. 18: Disengage the fuel injector's and the camshaft sensor's wiring connectors



Click image to see an enlarged view

Fig. Fig. 19: The mounting bolts for the intake manifold should be tightened from the center of the manifold, progressing outward in both directions

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure, as described in Fuel System .
  4.  
  5. Drain the cooling system, as described in Routine Maintenance .
  6.  
  7. Remove the fresh air duct from the air filter housing. Remove the inlet hose from the intercooler.
  8.  
  9. Remove the radiator hose from the thermostat housing.
  10.  
  11. Remove the DIS ignition coil from the intake manifold.
  12.  
  13. Disconnect the throttle and cruise control cables (if equipped) from the throttle body.
  14.  
  15. Disconnect the intercooler-to-throttle body outlet hose. Disconnect the vacuum hoses from the throttle body and carefully remove the harness.
  16.  
  17. Disconnect the AIS motor and TPS wiring connectors.
  18.  
  19. Remove the PCV breather/separator box and vacuum harness assembly. Remove the brake booster hose, vacuum vapor harness and fuel pressure regulator from the intake manifold.
  20.  
  21. Disconnect the fuel injector wiring harness and charge temperature sensor.
  22.  
  23. Wrap shop towels around the fittings and disconnect the fuel supply and return fuel lines.
  24.  
  25. Remove the intake manifold retaining bolts and remove the manifold from the cylinder head.
  26.  

To install:
  1. Inspect the manifold for damage of any kind. Thoroughly clean and dry the mating surfaces.
  2.  
  3. Install the new gasket and manifold on the cylinder head. Starting at the center and working outwards, torque the bolts gradually and evenly to 17 ft. lbs. (23 Nm).
  4.  
  5. Lubricate the quick connect fuel fittings with oil and connect to the chassis tubes. Ensure they are locked by pulling on them.
  6.  
  7. Install the PCV breather/separator box and vacuum harness assembly. Connect the brake booster hose, vacuum vapor harness and fuel pressure regulator to the intake manifold.
  8.  
  9. Connect the fuel injector wiring harness and charge temperature sensor. Connect the AIS motor and TPS wiring connectors.
  10.  
  11. Connect the vacuum hoses to the throttle body and carefully install the harness. Connect the intercooler-to-throttle body outlet hose.
  12.  
  13. Connect the throttle and speed control cables to the throttle body.
  14.  
  15. Install the DIS ignition coil to the intake manifold.
  16.  
  17. Connect the radiator hose to the thermostat housing.
  18.  
  19. Install the inlet hose on the intercooler. Install the fresh air duct on the air filter housing.
  20.  
  21. Refill and bleed the cooling system. Connect the negative battery cable. Start the engine and check for leaks.
  22.  

EXHAUST MANIFOLD
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the turbocharger assembly.
  4.  
  5. Remove the coolant tube from the cylinder head.
  6.  
  7. Remove the exhaust manifold retaining nuts and remove the manifold.
  8.  
  9. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
  10.  

To install:
  1. Install a new exhaust manifold gasket. Do not use sealer of any kind.
  2.  
  3. Position the manifold on the studs and install the retaining nuts. Starting at the center and working outwards, torque the nuts gradually and evenly to 17 ft. lbs. (23 Nm).
  4.  
  5. Using a new gasket, connect the coolant tube to the cylinder head.
  6.  
  7. Install the turbocharger assembly.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check for exhaust leaks.
  12.  

2.5L Turbo I Engine

See Figures 20 through 24

Click image to see an enlarged view

Fig. Fig. 20: Exploded view of the intake manifold, exhaust manifold and turbocharger mounting-Tighten all fasteners to the specifications shown



Click image to see an enlarged view

Fig. Fig. 21: Exploded view of the air inlet and air cleaner system for the 2.5L Turbo I engine



Click image to see an enlarged view

Fig. Fig. 22: Detach all vacuum, electrical and fuel connections from the cylinder head and throttle body



Click image to see an enlarged view

Fig. Fig. 23: To remove the intake manifold, the fuel rail must be temporarily relocated-remove the fuel rail hold-down bolts



Click image to see an enlarged view

Fig. Fig. 24: Location of the intake and exhaust manifold mounting bolts

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the turbocharger, as described later in this section.
  4.  
  5. Remove the 8 intake manifold bolts and washers, then remove the intake manifold from the cylinder head.
  6.  
  7. Remove the 8 exhaust manifold bolts and washers, then remove the exhaust manifold from the cylinder head.
  8.  

To install:
  1. Discard the gaskets and clean all gasket surfaces on both manifolds and on the cylinder head.
  2.  
  3. Test the gasket surfaces of the manifolds for flatness with a straightedge. Surface warpage must not exceed 0.006 in. (0.15mm) per foot (30cm) of manifold length.
  4.  
  5. Inspect the manifolds for cracks and distortion; replace the manifolds if any such damage is evident.
  6.  
  7. Install a new Grafoil or equivalent combination manifold gasket. DO NOT coat the gasket with sealer.
  8.  
  9. Position the lower intake manifold against the cylinder head and install the mounting bolts. Tighten the mounting bolts by starting at the center and progressing outward in both directions to 17 ft. lbs. (23 Nm).
  10.  
  11. Position the exhaust manifold against the cylinder head and install the mounting bolts. Tighten the mounting bolts by starting at the center and progressing outward in both directions to 17 ft. lbs. (23 Nm).
  12.  
  13. Install the cowl mounted heat shield.
  14.  
  15. Install the turbocharger, as described later in this section.
  16.  
  17. Install the fuel rail onto the intake manifold. For complete instructions, refer to Fuel System .
  18.  
  19. Connect the negative battery cable.
  20.  

2.5L Premier Engine

See Figures 25 and 26

Click image to see an enlarged view

Fig. Fig. 25: Make sure to install the exhaust manifold alignment spacers as shown



Click image to see an enlarged view

Fig. Fig. 25: The exhaust/intake manifold assembly bolts must be tightened in the sequence shown

  1. Relieve the fuel system pressure, as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  6.  
  7. Disconnect the exhaust system from the exhaust manifold.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the air inlet cover and hose from the throttle body.
  12.  
  13. Loosen the accessory drive belt and remove it, as described in Routine Maintenance .
  14.  
  15. Remove the power steering pump and brackets. Support the pump aside, but do not disconnect the pressure lines. For more details, refer to Suspension & Steering .
  16.  
  17. Disconnect the fuel lines and the accelerator cable from the throttle body. Disengage the electrical connectors for the idle speed sensor, throttle position sensor, coolant temperature sensor, air intake temperature sensor and the oxygen sensor.
  18.  
  19. Disconnect the electrical plug from the fuel injector. Disconnect all vacuum lines from the intake manifold.
  20.  
  21. Remove the bolts supporting the EGR tube to the exhaust manifold.
  22.  
  23. Remove the heater hoses from the intake manifold.
  24.  
  25. Remove the intake/exhaust manifold mounting bolts, then remove the manifolds from the engine.
  26.  

To install:
  1. Clean all of the gasket mounting surfaces.
  2.  
  3. Position the new intake manifold gasket and the new exhaust manifold spacers over the locating dowels, then install the manifold to the head. Finger-tighten the manifold retaining bolts.
  4.  
  5. Install the EGR tube with a new gasket to the exhaust manifold. Finger-tighten the No. 9 and 10 bolts. Leave the EGR tube nut at the manifold finger-tight.
  6.  
  7. Tighten the manifold fasteners in sequence to the specified torque, as follows:

    Fasteners No. 1, 6, 7 and 8-30 ft. lbs. (41 Nm)
     
    Fasteners No. 2, 3, 4 and 5-23 ft. lbs. (31 Nm)
     
    Fasteners No. 9 and 10-14 ft. lbs. (19 Nm)
     

  8.  
  9. Connect the heater and vacuum hoses. Attach the fuel lines to the throttle body, as described in Fuel System .
  10.  
  11. Reattach all electrical connectors.
  12.  
  13. Install the power steering pump and brackets. For more information, refer to Suspension & Steering .
  14.  
  15. Connect the accelerator cable to the throttle body.
  16.  
  17. Install the accessory drive belt and adjust the tension, as described in Routine Maintenance .
  18.  
  19. Install the air inlet tube and cover.
  20.  
  21. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  22.  
  23. Connect the exhaust system to the exhaust manifold, as described later in this section.
  24.  
  25. Lower the vehicle and remove the wheel blocks.
  26.  
  27. Connect the negative battery cable and fill the cooling system.
  28.  
  29. Run the engine and bleed the cooling system. Check for leaks.
  30.  

2.6L Engine
INTAKE MANIFOLD
  1. Disconnect the battery negative cable.
  2.  
  3. Drain the cooling system, as described in Routine Maintenance .
  4.  
  5. Disconnect the coolant hose running from the water pump to the intake manifold.
  6.  
  7. Disconnect the carburetor air intake hose and move it out of the way.
  8.  
  9. Label and disconnect all vacuum hoses connected to the intake manifold and carburetor.
  10.  
  11. Disconnect the throttle linkage at the carburetor and move it out of the way.
  12.  
  13. Disconnect the inlet line at the fuel filter, collecting any gasoline that spills out in a metal cup. Then, remove the fuel filter and pump and move them to one side.
  14.  
  15. Remove the mounting nuts and accompanying washers from the manifold attaching studs, and remove the manifold from the engine.
  16.  

To install:
  1. Clean all gasket surfaces and install the intake manifold using new gaskets. Tighten the bolts in three stages to 17 ft. lbs. (23 Nm).
  2.  
  3. Reinstall the fuel pump and fuel filter, as described in Fuel System . Connect the inlet line and clamp it securely.
  4.  
  5. Reconnect the throttle linkage to the carburetor and adjust it to eliminate excessive play. For more details, refer to Fuel System .
  6.  
  7. Reconnect all the vacuum hoses to the intake manifold and carburetor, according to the labels made earlier.
  8.  
  9. Connect the carburetor air intake hose to the carburetor and clamp it securely.
  10.  
  11. Connect the coolant hose running from the water pump to the intake manifold. For more details regarding cooling system hose clamp tightening and positioning, refer to Routine Maintenance .
  12.  
  13. Refill the cooling system with 50/50 mixture of antifreeze and water. For more details, refer to Routine Maintenance .
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine and check for fluid leaks. After the engine reaches operating temperature, shut it OFF . When it has cooled, refill the cooling system, if necessary.
  18.  

EXHAUST MANIFOLD
  1. Remove air cleaner.
  2.  
  3. Remove the heat shield from the exhaust manifold. Remove the EGR lines and reed valve, if equipped.
  4.  
  5. Unbolt the exhaust flange connection.
  6.  
  7. Remove the nuts holding manifold to the cylinder head.
  8.  
  9. Remove the manifold.
  10.  
  11. Installation is the reverse of removal. Tighten flange connection bolts to 11-18 ft. lbs. (15-25 Nm). Tighten the manifold bolts to 11-14 ft. lbs. (15-19 Nm).
  12.  

 
label.common.footer.alt.autozoneLogo