GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Intake Manifold

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REMOVAL & INSTALLATION




CAUTION
When draining the 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.

1.8, 2.0L and 2.2L OHV Engines
1982-86 VEHICLES

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner. Drain the cooling system.
  4.  
  5. Tag and disconnect all necessary vacuum lines and wires.
  6.  
  7. Remove the idler pulley.
  8.  
  9. If equipped, remove the A.I.R. drive belt. If equipped with power steering, remove the drive belt and then remove the pump with the lines attached. Position the pump out of the way.
  10.  
  11. If equipped, remove the A.I.R. bracket-to-intake manifold bolt. Remove the air pump pulley.
  12.  
  13. If equipped with power steering, remove the A.I.R. through-bolt and then the power steering adjusting bracket.
  14.  
  15. Loosen the lower bolt on the air pump mounting bracket so that the bracket will rotate.
  16.  


CAUTION
The fuel lines are pressurized (especially with fuel injection). Removal may cause fuel spray resulting in personal injury. Do not remove before bleeding the pressure from the fuel system. see Routine Maintenance for the procedure.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the fuel lines at the carburetor or TBI unit. Detach the carburetor or TBI linkage and then remove the carburetor or TBI unit.
  4.  
  5. Lift off the Early Fuel Evaporation (EFE) heater grid.
  6.  
  7. Remove the distributor. For details, please refer to Engine Electrical of this repair guide.
  8.  
  9. Unfasten the mounting bolts and nuts, then remove the intake manifold. Make sure to disconnect the heater hose and condenser from the bottom of the intake manifold before you lift it all the way out.
  10.  
  11. Clean the intake manifold-to-cylinder head mating surfaces. Be sure to clean all of old gasket material off.
  12.  

To install:
  1. Place a new gasket on the cylinder head, then position the manifold. Tighten the nuts and bolts to 20-25 ft. lbs. (27-34 Nm), working from the center position to the end position.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Removing the intake manifold - 1982-86 OHV engines

  1. Installation of the remaining components is in the reverse order of removal. Adjust all necessary drive belts and check the ignition timing.
  2.  

1987-91 VEHICLES

See Figure 2


CAUTION
Fuel injected vehicles maintain high fuel pressure within the fuel system, even after the engine has been shut off. Fuel system residual pressure must be properly relieved, prior to attempting this procedure; failure to do so can result in serious personal injury and/or property damage.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner. Properly drain the cooling system into an approved container.
  4.  
  5. Tag and disconnect all necessary vacuum lines and wires from the intake manifold and throttle body.
  6.  
  7. Disconnect and cap the fuel lines from the throttle body.
  8.  
  9. Detach the control cables from the throttle body lever.
  10.  
  11. Unfasten the throttle body mounting screws, then remove the throttle body from the intake manifold.
  12.  
  13. Remove the serpentine belt.
  14.  
  15. Unfasten the power steering pump-to-bracket bolts and support the pump out of the way. DO NOT disconnect the power steering hoses from the pump.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Remove the control cable bracket from the intake manifold.
  20.  
  21. Disconnect the heater (coolant) hose from the bottom of the intake manifold.
  22.  
  23. Unfasten the lower intake manifold bolts.
  24.  
  25. Carefully lower the vehicle.
  26.  
  27. Unfasten the intake manifold-to-cylinder head nuts/bolts, then remove the intake manifold.
  28.  
  29. Use a gasket scraper to carefully clean the gasket mating surfaces.
  30.  



Click image to see an enlarged view

Fig. Fig. 2: When installing the intake manifold, you must use the correct tightening sequence, or leaks may occur

To install:
  1. Position a new gasket, then install the intake manifold and tighten the manifold-to-cylinder head nuts/bolts (in the proper sequence) to 18 ft. lbs. (25 Nm).
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Connect the heater hose to the underside of the intake manifold.
  6.  
  7. Install the control cable bracket to the intake manifold.
  8.  
  9. Carefully lower the vehicle.
  10.  
  11. Install the power steering pump in the mounting bracket, then tighten the mounting bolts.
  12.  
  13. Position the throttle body assembly on the intake manifold, then tighten the mounting bolts to 17 ft. lbs. (23 Nm).
  14.  
  15. Connect the control cables to the throttle body lever, then attach the fuel lines to the throttle body.
  16.  
  17. Attach the vacuum lines and wires, as tagged during removal.
  18.  
  19. Install the air cleaner assembly.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Properly fill the cooling system.
  24.  
  25. Pressurize the fuel system before starting the vehicle, and make sure there are no leaks.
  26.  
  27. Start the engine and check for oil and/or coolant leaks.
  28.  

1992-94 VEHICLES

See Figures 3 and 4

These vehicles use a two-piece intake manifold. The upper half, sometimes called a plenum, contains the throttle body and the control cable connections. The lower half has individual port runner to each intake port on the cylinder head. The lower half of the manifold bolts to the cylinder head and houses the fuel injectors. Note that these pieces are cast aluminum. Care should be exercised when working with any light allow component.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the throttle body air intake duct.
  6.  
  7. Drain the cooling system into an approved container.
  8.  
  9. Identify, tag and disconnect all necessary vacuum lines.
  10.  
  11. Disconnect the control cables from the throttle body lever and remove the control cable bracket form the intake manifold.
  12.  
  13. Remove the serpentine belt.
  14.  
  15. Remove the power steering pump and lay it aside with the fluid lines attached.
  16.  
  17. Remove the transaxle fill tube.
  18.  
  19. Tag and disconnect the following electrical wires:

    Idle Air Control (IAC) valve
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    EVAP Emission solenoid
     
    Fuel injector harness
     
    Exhaust Gas Recirculation (EGR) valve
     

  20.  
  21. Remove the MAP sensor.
  22.  
  23. Unfasten the upper intake manifold mounting bolts, then remove the upper intake manifold.
  24.  
  25. Disconnect the fuel lines from the fuel rail.
  26.  
  27. Remove the EGR valve injector, then remove the EGR valve.
  28.  
  29. Remove the fuel injector retainer bracket, regulator and injectors.
  30.  
  31. Unfasten and remove the control cable bracket.
  32.  
  33. If necessary for access, raise and safely support the vehicle.
  34.  
  35. Unfasten the six intake manifold nuts, then remove the manifold.
  36.  
  37. Clean the gasket mounting surfaces.
  38.  

To install:
  1. Install a new gasket, then position the lower intake manifold. Tighten the lower intake manifold nuts in the proper sequence to 24 ft. lbs. (33 Nm).
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Lower intake manifold tightening sequence - 1992-94 OHV vehicles

  1. Connect the control cables and cable bracket.
  2.  
  3. Install the EGR valve.
  4.  
  5. Attach the fuel lines to the fuel rail.
  6.  
  7. Install the fuel injectors, regulator and injector retainer bracket, then tighten the retaining bolts to 22 inch lbs. (3.5 Nm).
  8.  
  9. Install the EGR valve injector so that the port is facing directly towards the throttle body.
  10.  
  11. Install the upper intake manifold assembly. Tighten the upper intake manifold nuts in the proper sequence to 22 ft. lbs. (30 Nm).
  12.  



Click image to see an enlarged view

Fig. Fig. 4: The upper manifold bolts to the lower one, but be sure to use the correct sequence when tightening

  1. Install the MAP sensor.
  2.  
  3. Attach the electrical connectors to the MAP sensor, EGR solenoid valve, Idle Air Control (IAC) valve, Throttle Position (TP) sensor, and the fuel injectors.
  4.  
  5. Install the transaxle fill tube.
  6.  
  7. Install the power steering pump, then install the serpentine belt.
  8.  
  9. Connect the vacuum lines, as tagged during removal.
  10.  
  11. Install the air intake duct.
  12.  
  13. Refill the coolant system.
  14.  
  15. Connect the negative battery cable, then start the engine and check for leaks.
  16.  

1.8L and 2.0L OHC Engines
EXCEPT TURBO

See Figure 5

  1. Release the fuel pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly drain the cooling system into an approved container.
  6.  
  7. Remove the alternator and bracket at the camshaft carrier.
  8.  
  9. Remove the power steering pump, then position it aside with the lines still attached.
  10.  
  11. Remove the ignition coil.
  12.  
  13. Disconnect the throttle cable from the intake manifold bracket.
  14.  
  15. Detach the throttle and TV cables from the throttle body.
  16.  
  17. Disconnect the wiring from the throttle body.
  18.  
  19. Detach the vacuum brake hose at the filter.
  20.  
  21. Disconnect the coolant hoses at the water pump and intake manifold and the inlet tube-to-water pump.
  22.  
  23. For access to the lower retaining nuts, detach the ECM electrical harness.
  24.  
  25. Unfasten the retaining nuts and washers, then remove the intake manifold. Clean the mating surfaces of the cylinder head and intake manifold.
  26.  



Click image to see an enlarged view

Fig. Fig. 5: Intake manifold mounting - 1.8L and 2.0L OHC engines; EXCEPT turbo

To install:
  1. Place a new gasket on the cylinder head, then position the intake manifold. Tighten intake manifold retaining nuts and washers evenly in sequence to 20-25 ft. lbs. (27-34 Nm) for 1982-86 and 16 ft. lbs. (22 Nm) for 1987-92. Start with the inner nuts and work outward.
  2.  
  3. Attach the ECM wiring harness.
  4.  
  5. Connect the coolant hoses at the water pump and intake manifold and the inlet tube-to-water pump.
  6.  
  7. Fasten the inlet and return fuel lines.
  8.  
  9. Connect the vacuum brake hose at the filter.
  10.  
  11. Attach the wiring at the throttle body.
  12.  
  13. Connect the throttle and TV cables to the throttle body. Attach the throttle cable to the intake manifold bracket.
  14.  
  15. Install the ignition coil.
  16.  
  17. Attach the power steering bracket to the intake manifold.
  18.  
  19. Install the power steering pump.
  20.  
  21. Attach the alternator and bracket to the camshaft carrier.
  22.  
  23. Fill the engine cooling system.
  24.  
  25. Install the air cleaner.
  26.  
  27. Connect the negative battery cable, then start the engine and check for leaks.
  28.  

TURBO

See Figures 6 and 7

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into an approved container.
  6.  
  7. Unfasten the induction tube and hoses.
  8.  



Click image to see an enlarged view

Fig. Fig. 6: Disconnect the turbo injection tube and hoses

  1. Detach the wiring to the throttle body, Manifold Absolute Pressure (MAP) sensor and the wastegate.
  2.  
  3. Disconnect the PCV hose, then detach the vacuum hose from the throttle body.
  4.  
  5. Detach the throttle cable and, if equipped, the cruise control cable.
  6.  
  7. Disconnect the wiring from the ignition coil.
  8.  
  9. Remove the manifold support bracket.
  10.  
  11. Unfasten the bolt attaching the rear alternator bracket to the alternator.
  12.  
  13. Remove the power steering adjusting bracket and the alternator front adjusting bracket.
  14.  
  15. Disconnect the fuel lines from the fuel rail inlet and the regulator outlet.
  16.  
  17. Unfasten the retaining nuts and washers, then remove the intake manifold and gasket. If installing a new manifold, don't forget to transfer all necessary parts from the old manifold to the new one.
  18.  
  19. Clean the cylinder head and intake manifold mating surfaces so they are clean of old gasket material and other debris.
  20.  



Click image to see an enlarged view

Fig. Fig. 7: Removing the intake manifold - 2.0L turbo engine

To install:
  1. Place a new gasket on the cylinder head, then position the intake manifold. Tighten the retaining nuts and washers to 18 ft. lbs. (25 Nm).
  2.  
  3. Attach the fuel lines to the regulator outlet and fuel rail inlet.
  4.  

Any time the rear power steering adjusting bracket is loosened or removed, proper adjusting bolt torque is essential for belt and pulley alignment. The rear adjusting bracket must be the last part secured to prevent distorting the accessory drive system to prevent the belt from coming off.

  1. Install the power steering and alternator adjusting brackets.
  2.  
  3. Attach the wiring to the fuel injectors and ignition coil.
  4.  
  5. Connect the throttle cable and cruise control cable, if applicable.
  6.  
  7. Attach the vacuum hoses and PCV hose.
  8.  
  9. Connect the wiring to the throttle body, MAP sensor and wastegate.
  10.  
  11. Attach the induction tube and hoses.
  12.  
  13. Fill the engine cooling system.
  14.  
  15. Connect the negative battery cable, then start the engine and check for vacuum and/or fluid leaks and proper engine operation.
  16.  

2.8L and 3.1L Engines
1985-88 VEHICLES

See Figure 8

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Detach the accelerator and TV cable bracket at the plenum.
  6.  
  7. Unfasten the throttle body at the plenum.
  8.  
  9. Disconnect the EGR pipe from the EGR valve.
  10.  
  11. Remove the plenum assembly.
  12.  
  13. Detach the fuel inlet and outlet pipes at the fuel rail.
  14.  
  15. Disconnect the serpentine drive belt.
  16.  
  17. Remove the power steering pump mounting bracket.
  18.  
  19. Detach the heater pipe at the power steering pump bracket.
  20.  
  21. Tag and disconnect the wiring at the alternator, then remove the alternator.
  22.  
  23. Disconnect the wires from the cold start injector assembly. Remove the injector assembly from the intake manifold.
  24.  
  25. Disconnect the idle air vacuum hose at the throttle body. Detach the wires at the injectors.
  26.  
  27. Remove the fuel rail, breather tube and the fuel runners from the engine.
  28.  
  29. Tag and disconnect the coil wires.
  30.  
  31. Remove the rocker arm covers.
  32.  
  33. Drain the cooling system, the disconnect the radiator hose at the thermostat housing. Disconnect the heater hose from the thermostat housing and the thermostat wiring.
  34.  
  35. Remove the distributor.
  36.  
  37. Remove the thermostat assembly housing.
  38.  
  39. Unfasten the intake manifold bolts and remove the intake manifold from the engine.
  40.  

To install:


Click image to see an enlarged view

Fig. Fig. 8: Intake manifold installation and retaining bolt torque sequence - 1985 2.8L engine shown

  1. The gaskets are marked for right and left side installation; do not interchange them. Clean the sealing surfaces of the engine block and intake manifold, and apply a 3 / 16 in. (5mm) wide bead of silicone sealer to each ridge.
  2.  
  3. Place the new gaskets onto the heads. The gaskets will have to be cut slightly to fit past the center pushrods. Do not cut any more material than necessary. Hold the gaskets in place by extending the ridge bead of sealer 1 / 4 in. (6mm) onto the gasket ends.
  4.  
  5. Position the intake manifold. The area between the ridges and the manifold should be completely sealed.
  6.  
  7. Install the retaining bolts and nuts, and tighten in sequence to 23 ft. lbs. (31 Nm). Do not overtighten; the manifold is made from aluminum, and can be warped or cracked with excessive force.
  8.  
  9. The rest of installation is the reverse of removal. Adjust the ignition timing after installation, and check the coolant level after the engine has warmed up.
  10.  

1989-93 VEHICLES

See Figure 9

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Detach the cables at the plenum.
  6.  
  7. Unfasten the brake vacuum pipe at the plenum.
  8.  
  9. Disconnect the throttle body and the EGR pipe from the EGR valve.
  10.  
  11. Remove the plenum assembly.
  12.  
  13. Disconnect the fuel line along the fuel rail.
  14.  
  15. Remove the serpentine drive belt.
  16.  
  17. Unfasten the alternator, then move it to one side. Loosen the alternator bracket.
  18.  
  19. Remove the power steering pump and move to one side.
  20.  
  21. Disconnect the idle air vacuum hose at the throttle body.
  22.  
  23. Detach the the wires at the fuel injectors.
  24.  
  25. Remove the fuel rail, breather tube and the fuel runners from the engine.
  26.  
  27. Tag and disconnect the plug wires at the manifold.
  28.  
  29. Remove the rocker arm covers; refer to the necessary service procedure located in this section.
  30.  
  31. Drain the cooling system, the disconnect the radiator hose at the thermostat housing. Disconnect the heater hose from the thermostat housing and tag and disconnect the thermostat wiring.
  32.  
  33. Unfasten the intake manifold bolts and remove the intake manifold from the engine.
  34.  

Retain the Belleville washer in the same orientation on the 4 center bolts.

  1. Loosen the rocker arms and remove the pushrods.
  2.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Remove and discard the intake manifold gasket.
  2.  

To install:
  1. Clean the gasket material and grease from the mating surfaces.
  2.  
  3. Place a 0.08-0.12 in. (2-3mm) bead of RTV sealant on each ridge where the front and rear of the intake manifold contact the block.
  4.  
  5. Install the new intake manifold gasket.
  6.  
  7. Install the pushrods and make sure they are seated properly in the lifter.
  8.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Install the rocker arm nuts and tighten to 18 ft. lbs. (24 Nm).
  2.  
  3. Install the intake manifold and retaining bolts. Tighten the bolts to 15 ft. lbs. (20 Nm) in the proper sequence shown, then retighten in sequence to 24 ft. lbs. (33 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 9: Make sure to tighten the intake manifold retaining bolts in the proper sequence - 1993 3.1L engine shown

  1. Install the heater pipe to the manifold.
  2.  
  3. Connect the coolant sensor and any other necessary wiring.
  4.  
  5. Fasten the upper radiator hose.
  6.  
  7. Install the rocker arm covers.
  8.  
  9. Connect the breather tube.
  10.  
  11. Install the fuel rail and attach the wires to the injectors.
  12.  
  13. Connect the idle air vacuum hose at the throttle body.
  14.  
  15. Install the alternator and bracket.
  16.  
  17. Install the power steering gear and pump.
  18.  
  19. Connect the power steering line at the alternator bracket.
  20.  
  21. Install the serpentine drive belt.
  22.  
  23. Connect the fuel lines to the fuel rail and to the bracket.
  24.  
  25. Install the plenum, plug harness and EGR valve.
  26.  
  27. Install the throttle body.
  28.  
  29. Attach the cables at the plenum.
  30.  
  31. Connect the negative battery cable and fill the cooling system.
  32.  

1994 VEHICLES

See Figure 10

On 3.1L engines, an "Idle Learn" procedure must be performed which requires the use of a scan tool.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the battery and the air cleaner assembly.
  6.  
  7. Remove the serpentine belt.
  8.  
  9. Unfasten and remove the exhaust crossover pipe.
  10.  
  11. Disconnect the EGR transfer tube from the exhaust manifold.
  12.  
  13. Properly drain and recover the engine cooling system.
  14.  
  15. Remove the radiator surge or overflow tank.
  16.  
  17. Disconnect the brake vacuum pipe at the plenum.
  18.  
  19. Remove the throttle cable and the vacuum line bracket at the plenum.
  20.  
  21. Disconnect the power steering lines at the alternator bracket.
  22.  
  23. Unfasten the rear alternator brace, then remove the alternator.
  24.  
  25. Tag and disconnect the spark plug wires from the plug, then unroute them.
  26.  
  27. Remove the rear valve (rocker arm) cover. For details, please refer to the procedure located in this section.
  28.  
  29. Tag and disconnect, then unroute the following electrical connections:

    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) sensor
     
    Exhaust Gas Recirculation (EGR) valve
     
    Engine Coolant Temperature (ECT) sensor
     
    Fuel injector wiring harness connector
     

  30.  
  31. Tag and disconnect the PCV hose and any other necessary vacuum lines.
  32.  
  33. Detach the cables at the throttle body.
  34.  
  35. Unfasten the throttle body heater hoses.
  36.  
  37. Remove the plenum.
  38.  
  39. Disconnect the fuel lines from the fuel rail and the fuel lines at the bracket.
  40.  
  41. Unfasten the power steering pump mounting bolts, then position the pump aside with the lines attached.
  42.  
  43. Disconnect the coolant bleed pipe from the thermostat housing.
  44.  
  45. Detach the heater pipe from the cylinder heads, thermostat housing and the water pump. Disconnect the upper radiator hose at the themostat housing.
  46.  
  47. Remove the thermostat housing.
  48.  
  49. As outlined earlier, remove the front valve (rocker arm) cover.
  50.  

When removing the manifold, make sure to retain the washers in the same orientation on the 4 center bolts.

  1. Unfasten the retaining bolts and/or nuts, then remove the intake manifold.
  2.  
  3. Loosen the rocker arms, then remove the pushrods.
  4.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Remove and discard the intake gasket, then clean the mating surfaces free of gasket material and old RTV sealant.
  2.  



Click image to see an enlarged view

Fig. Fig. 10: When removing the intake manifold, be sure to keep the washers in the same orientation on the 4 center bolts

To install:
  1. Place a 0.08-0.12 in. (2-3mm) bead of RTV sealant on each ridge where the front and rear of the intake manifold contact the block.
  2.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Position a new intake manifold gasket, then install the pushrods, making sure they seat in the lifters.
  2.  
  3. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
  4.  
  5. Position the intake manifold, then tighten the retaining bolts, in the proper sequence, in two steps; first to 15 ft. lbs. (20 Nm), then to 24 ft. lbs. (33 Nm).
  6.  
  7. Install the front valve (rocker arm) cover.
  8.  
  9. Attach the heater pipe to the manifold.
  10.  
  11. Install the thermostat housing, then attach the upper radiator hose to the housing.
  12.  
  13. Connect the heater pipe to the cylinder heads, water pump and themostat housing.
  14.  
  15. Attach the coolant bleed pipe to the thermostat housing.
  16.  
  17. Install the power steering pump.
  18.  
  19. Attach the fuel lines to the fuel rail, the fasten fuel lines at the bracket.
  20.  
  21. Install the plenum.
  22.  
  23. Attach the throttle body heater hoses, then connect the cables to the throttle body.
  24.  
  25. Connect the PCV hose, and any other vacuum lines disconnected during removal.
  26.  
  27. Route and attach the following electrical connections, as tagged during removal:

    TP sensor
     
    IAC valve
     
    EGR valve
     
    ECT sensor
     
    Fuel injector wiring harness connector
     

  28.  
  29. Install the rear valve (rocker arm) cover.
  30.  
  31. Route and connect all spark plug wires, as tagged during removal.
  32.  
  33. Install the alternator and the alternator brace, then attach the power steering line to the brace.
  34.  
  35. Attach the throttle cable and vacuum lines bracket to the plenum.
  36.  
  37. Connect the brake vacuum pipe to the plenum.
  38.  
  39. Install the radiator surge or overflow tank.
  40.  
  41. Attach the EGR transfer tube to the exhaust manifold.
  42.  
  43. Connect the exhaust crossover to the exhaust manifolds.
  44.  
  45. Install the air cleaner assembly and the battery, then connect the negative battery cable.
  46.  

On the 3.1L engine, a Tech 1® scan tool is needed to perform the "Idle Learn" procedure.

  1. For the 3.1L engine perform the following "Idle Learn" procedure;
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle in park or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  2.  
  3. Fill the cooling system, then start the engine and check for leaks.
  4.  

 
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