ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Intake Manifold

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REMOVAL & INSTALLATION



1.8L and 2.0L Engines

See Figure 1



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Fig. Fig. 1: Intake manifold assembly-1.8L and 2.0L engines

  1. Drain the cooling system and disconnect the battery cables.
  2.  


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.

Before removing the intake manifold, check to make certain the engine coolant is completely drained. If any water remains in the block it will flow into the cylinders when the intake manifold is removed.

  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the radiator hose from the front part of the intake manifold.
  4.  
  5. Disconnect the fuel lines, all vacuum lines and the carburetor control cable.
  6.  
  7. Disconnect the heater hoses from the rear part of the manifold and from the connector under the dashboard.
  8.  
  9. Disconnect the distributor vacuum hose and all thermo-valve wiring. Disconnect the electric choke or solenoid wires.
  10.  

Tag all wires before disconnecting them.

  1. Disconnect the PCV hose from the rocker cover. Disconnect the EGR valve from the EGR pipe and disconnect the air injection vacuum hose from the three-way connector.
  2.  
  3. Remove the eight nuts attaching the intake manifold and lift it clear, being careful not to snag any loose lines.
  4.  

To install:
  1. Check the manifold for cracks or damage. The manifold head surfaces can be checked for distortion by using a straightedge and a feeler gauge. Distortion should be no more than 0.0157 in. (0.4mm), if it is beyond the limit, the distortion has to be corrected with a surface grinder.
  2.  
  3. Clean all gasket mating surfaces with a scraper and solvent.
  4.  
  5. Replace all gaskets and torque all nuts in sequence to 25-32 ft. lbs. (34-43 Nm).
  6.  
  7. Connect the PCV hose to the rocker cover. Connect the EGR valve to the EGR pipe and connect the air injection vacuum hose to the three-way connector.
  8.  
  9. Connect the distributor vacuum hose and all thermo-valve wiring. Connect the electric choke or solenoid wires.
  10.  
  11. Connect the heater hoses to the rear part of the manifold and to the connector under the dashboard.
  12.  
  13. Connect the fuel lines, all vacuum lines and the carburetor control cable.
  14.  
  15. Connect the radiator hose to the front part of the intake manifold.
  16.  
  17. Install the air cleaner assembly.
  18.  
  19. Refill the cooling system, connect the battery cables and check for leaks.
  20.  

Diesel Engine

See Figure 2



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Fig. Fig. 2: Intake manifold assembly-diesel engine

  1. Open the hood and disconnect the battery. Remove the air cleaner assembly.
  2.  
  3. Remove the connecting hose and PCV hose.
  4.  
  5. Remove the sensing resistor assembly.
  6.  
  7. Remove the 6 screws attaching the injection pipe clips and remove the injection pipe.
  8.  
  9. Remove the 10 bolts attaching the upper dust cover and remove the upper dust cover.
  10.  
  11. Remove the 2 bolts attaching the engine hanger and remove the engine hanger.
  12.  
  13. Remove the 2 bolts attaching the stay and remove the stay. Remove the three bolts and two nuts attaching the intake manifold and lift off the manifold.
  14.  

To install:
  1. Clean the gasket mating surfaces with a scraper and solvent. Inspect the components for warpage, distortion and damage.
  2.  
  3. Using a new manifold gasket, install the manifold and torque the bolts to 13-18 ft. lbs. (19-25 Nm).
  4.  
  5. Install the 2 bolts attaching the engine hanger and hanger.
  6.  
  7. Install the 10 bolts attaching the upper dust cover and the upper dust cover.
  8.  
  9. Install the 6 screws attaching the injection pipe clips and the injection pipe.
  10.  
  11. Install the sensing resistor assembly.
  12.  
  13. Install the connecting hose and PCV hose.
  14.  
  15. Connect the battery cable, install the air cleaner assembly, start the engine and check for leaks.
  16.  

2.2L Gasoline Engine

See Figures 3 and 4



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Fig. Fig. 3: Upper intake manifold assembly-1996 2.2L engine



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Fig. Fig. 4: Lower intake manifold assembly-1996 2.2L engine

Wait until the engine has cooled to ambient air temperature before removing the intake manifold.

  1. Relieve the fuel pressure.
  2.  


CAUTION
Fuel injection systems remain under pressure even after the engine has been turned off. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and personal injury.

  1. Disconnect the negative battery cable and remove the air duct.
  2.  
  3. Drain the cooling system. Disconnect the upper radiator hose from the manifold. Disconnect the coolant hoses from the throttle body.
  4.  
  5. Remove the air duct hose from the intake plenum.
  6.  
  7. Remove the MAP and EGR valve and bracket assembly from the intake manifold.
  8.  
  9. Disconnect the accelerator linkage.
  10.  
  11. Disconnect and tag the vacuum lines and electrical connections.
  12.  
  13. Disconnect the fuel lines.
  14.  
  15. Remove the upper intake manifold.
  16.  
  17. Disconnect spark plug wires from the coil.
  18.  
  19. Remove the heater hose on the right side.
  20.  
  21. Remove the EGR inlet pipe.
  22.  
  23. Remove the lower intake manifold bolts.
  24.  
  25. Remove the lower intake manifold.
  26.  

To install:
  1. Inspect all intake manifold mating surfaces for warpage and other signs of damage. Replace or machine as necessary.
  2.  
  3. Using a new gasket, install the lower intake manifold to the cylinder head. Torque the mounting nuts and bolts to 24 ft. lbs. (33 Nm) starting in the center and working towards the ends.
  4.  
  5. Install the generator braces, spark plug wires and EGR inlet.
  6.  
  7. Install the heater hose and fuel lines. Connect the wiring.
  8.  
  9. Install the upper manifold and tighten bolts to 22 ft. lbs. (30 Nm).
  10.  
  11. Connect the vacuum hoses and wiring.
  12.  
  13. Install MAP and EGR valves.
  14.  
  15. Install the throttle cable and tighten bolts to 18 ft. lbs. (25 Nm).
  16.  
  17. Install the air intake duct.
  18.  
  19. Connect the battery cable.
  20.  

2.3L and 2.6L Engines

See Figures 5 and 6



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Fig. Fig. 5: Intake manifold assembly-2.3L engine



Click image to see an enlarged view

Fig. Fig. 6: Intake manifold assembly-2.6L engine

AMIGO AND PICK-UP

Wait until the engine has cooled to ambient air temperature before removing the intake manifold.

  1. Relieve the fuel pressure.
  2.  


CAUTION
Fuel injection systems remain under pressure even after the engine has been turned off. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and personal injury.

  1. Disconnect the negative battery cable and remove the air duct.
  2.  
  3. Drain the cooling system. Disconnect the upper radiator hose from the manifold. Disconnect the coolant hoses from the throttle body.
  4.  
  5. Remove the air regulator hose from the intake plenum.
  6.  
  7. Remove the EGR valve and bracket assembly from the intake manifold.
  8.  
  9. Disconnect the accelerator linkage. Disconnect and tag the vacuum lines and electrical connections.
  10.  
  11. Disconnect the fuel injector wiring harnesses. Disconnect the fuel line from the fuel rail.
  12.  
  13. Loosen the throttle body attaching nuts in a crisscross pattern. Remove the throttle body.
  14.  
  15. Loosen the upper intake manifold plenum nuts in a crisscross pattern. Remove the upper intake manifold plenum.
  16.  
  17. Remove the fuel injector rail and fuel injectors as an assembly.
  18.  
  19. Loosen the intake manifold nuts and bolts in a crisscross pattern. Then, remove the intake manifold nuts and bolts.
  20.  
  21. Remove the manifold from the cylinder head. If it sticks, tap it with a soft-faced mallet.
  22.  

To install:
  1. Inspect all intake manifold mating surfaces for warpage and other signs of damage. Replace or machine as necessary.
  2.  
  3. Using a new gasket, install the intake manifold to the cylinder head. Torque the mounting nuts and bolts to 16 ft. lbs. (22 Nm) starting in the center and working towards the ends.
  4.  
  5. Install new O-rings and cushion rings onto the fuel injectors and there mounting ports. Install the fuel injector rail with the injectors onto the manifold. Tighten the fuel injector rail securing bolts to 14 ft. lbs. (19 Nm).
  6.  
  7. Using a new gasket, install the upper intake manifold plenum to the intake manifold. Tighten the upper intake manifold plenum attaching bolts to 20 ft. lbs. (27 Nm).
  8.  
  9. Using a new gasket, install the throttle body to the plenum. Tighten the throttle body attaching bolts to 14 ft. lbs. (19 Nm).
  10.  
  11. Connect the accelerator linkage, vacuum lines, and electrical wiring.
  12.  
  13. Reconnect the fuel line using new washers.
  14.  
  15. Using a new gasket, install the EGR valve and bracket assembly to the intake manifold. Tighten the 22mm nut to 33 ft. lbs. (44 Nm), and the 8mm nut to 17 ft. lbs. (24 Nm).
  16.  
  17. Install the air regulator hose to the upper intake manifold plenum.
  18.  
  19. Install the upper coolant hoses to the manifold.
  20.  
  21. Install the air duct and connect the negative battery cable.
  22.  
  23. Refill and bleed the cooling system and check for leaks.
  24.  
  25. Adjust the accelerator linkage cable so there is 0.078 in. (2mm) of clearance.
  26.  
  27. Check for fuel leaks.
  28.  

RODEO
  1. Support the hood as far open as possible.
  2.  
  3. Relieve the fuel pressure:
    1. Remove the fuel filler cap.
    2.  
    3. Remove the fuel pump primary relay from the underhood relay box.
    4.  
    5. Start the engine and allow it to stall. After the engine stalls, crank it for an additional 30 seconds.
    6.  

  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Disconnect the throttle cable from the throttle body linkage.
  10.  
  11. Disconnect and remove the air intake duct.
  12.  
  13. Disconnect the vacuum hose from the EGR valve. If equipped, disconnect the EGR temperature sensor connector.
  14.  
  15. Disconnect the EGR fuel pressure control rubber hose.
  16.  
  17. Use a flare wrench to disconnect the EGR pipe fitting from the intake manifold.
  18.  


CAUTION
Fuel injection systems remain 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. Disconnect the fuel feed hose from the fuel rail.
  2.  
  3. Label and disconnect the coolant hoses from the intake manifold. Use a drain pan to catch any spilled coolant.
  4.  
  5. Disconnect the air regulator hose and connector from the lower rear of the intake manifold chamber.
  6.  
  7. Disconnect the throttle position sensor connector and disconnect the coolant hoses from the throttle body.
  8.  
  9. Loosen the throttle body mounting bolts, and then remove the throttle body from the intake manifold chamber.
  10.  
  11. Loosen the intake manifold chamber mounting nuts and bolts; then, remove the intake manifold chamber from the lower part of the manifold.
  12.  
  13. Disconnect the fuel injector wire harness clip (plastic wire tie).
  14.  
  15. Remove the fuel injector rail attaching bolts.
  16.  
  17. Label and disconnect the fuel injector wiring harness connectors.
  18.  
  19. Carefully lift the fuel rail and injectors from the intake manifold as an assembly.
  20.  
  21. Loosen the intake manifold mounting bolts and nuts in a crisscross sequence.
  22.  
  23. Remove the intake manifold from the engine. Clean any old gasket material from the cylinder head and intake manifold mating surfaces.
  24.  

To install:
  1. Install a new intake manifold gasket onto the cylinder head. Next, position the intake manifold onto its cylinder head mounting studs.
  2.  
  3. Install the intake manifold attaching bolts and nuts, Tighten the bolts and nuts in a two-step crisscross pattern beginning in the center and working outward. The final torque specification is 16 ft. lbs. (22 Nm).
  4.  
  5. Lubricate new O-rings with a small amount of clean engine oil; then, install them onto the fuel injectors. Next, install the fuel injectors into the fuel rail, if they were removed. Install the fuel injectors and fuel rail assembly onto the intake manifold. Tighten the fuel rail attaching bolts to 14 ft. lbs. (19 Nm).
  6.  
  7. Reconnect the fuel injector wiring harness connectors.
  8.  
  9. Install the fuel injector wiring harness clip wire tie.
  10.  
  11. Install the intake manifold chamber to the lower part of the manifold using a new gasket. Tighten the bolts and nuts to 20 ft. lbs. (27 Nm) in a two-step crisscross pattern.
  12.  
  13. Install a new throttle body gasket and then install the throttle body. Tighten the mounting bolts to 14 ft. lbs. (19 Nm).
  14.  
  15. Reconnect the throttle position sensor connector. Reconnect the coolant hoses to the throttle body.
  16.  
  17. Connect the EGR pipe to the intake manifold, torque the flange nut to 33 ft. lbs. (44 Nm).
  18.  
  19. Connect the EGR fuel pressure control rubber hose. If equipped, reconnect the EGR temperature sensor connector.
  20.  
  21. Connect the vacuum hose to the EGR valve.
  22.  
  23. Connect the air regulator hose and the air regulator connector.
  24.  
  25. Connect the coolant hoses to the intake manifold.
  26.  
  27. Connect the fuel feed hose to the fuel rail using new sealing washers.
  28.  
  29. Install the air intake duct and reconnect the vacuum hose.
  30.  
  31. Connect the throttle cable to the throttle body linkage and adjust as necessary.
  32.  
  33. Refill and bleed the cooling system.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Turn the ignition switch ON and check for fuel leaks at the fuel rail.
  38.  
  39. Check the manifold coolant hoses for leaks. Check the intake manifold mating surfaces for leaks.
  40.  

2.8L Engine

See Figures 7, 8 and 9



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Fig. Fig. 7: Removing the intake manifold bolts-2.8L engine



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Fig. Fig. 8: Carefully lift the intake manifold make sure all hoses and wires are disconnected-2.8L engine



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Fig. Fig. 9: Intake manifold installation and manifold torque sequence-2.8L and 3.1L engines

  1. Relieve the fuel pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner. Drain the cooling system.
  4.  


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. Label and disconnect the wires and hoses from the TBI unit and the intake manifold.
  2.  
  3. Disconnect and plug the fuel lines from the TBI unit.
  4.  
  5. Disconnect the accelerator cables from the TBI unit.
  6.  
  7. Disconnect the ignition wires from the spark plugs and the wires from the coil.
  8.  
  9. Remove the distributor cap with the wires.
  10.  
  11. Mark the location of the rotor to the distributor housing and the distributor housing to the intake manifold.
  12.  
  13. Remove the distributor hold-down clamp and the distributor.
  14.  
  15. Label and disconnect the EGR vacuum line and the emission hoses.
  16.  
  17. Remove the pipe brackets from the rocker arm covers.
  18.  
  19. Remove the rocker arm covers.
  20.  
  21. Remove the upper radiator hose and the heater hose.
  22.  
  23. Disconnect the electrical connectors from the coolant sensors.
  24.  
  25. Remove the intake manifold nuts/bolts, the manifold and gaskets.
  26.  
  27. Clean the gasket mounting surfaces.
  28.  

To install:
  1. Using RTV sealant, apply a 1 / 8 in. (3mm) bead to the front and rear of the block; make sure no water or oil is present.
  2.  
  3. Using new gaskets, marked right and left side, apply a 1 / 4 in. (6mm) bead of sealant to hold them in place and install them onto the cylinder heads; the gaskets may have to be cut to be installed around the pushrods.
  4.  
  5. Install the intake manifold and torque the nuts/bolts, in sequence, to 23 ft. lbs. (31 Nm) and retorque using the same sequence.
  6.  

Make sure the areas between the case ridges and the intake manifold are completely sealed.

  1. Install the heater hose and the radiator to the manifold.
  2.  
  3. Using new gaskets, install the rocker arm covers.
  4.  
  5. Connect the electrical connectors to the coolant sensors.
  6.  
  7. Install the pipe brackets.
  8.  
  9. Align the matchmarks and install the distributor and the distributor cap.
  10.  
  11. Connect the fuel lines and the accelerator cables to the TBI unit.
  12.  
  13. Connect all the wires and vacuum hoses.
  14.  
  15. Install the air cleaner. Connect the negative battery cable. Refill the cooling system.
  16.  

3.1L Engine

See Figures 10 and 11



Click image to see an enlarged view

Fig. Fig. 10: Intake manifold assembly-3.1L engine



Click image to see an enlarged view

Fig. Fig. 11: Intake manifold bolt tightening sequence-3.1L engine

  1. Relieve the fuel pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner. Drain the cooling system.
  4.  
  5. Label and disconnect the wires and hoses from the TBI unit and the intake manifold.
  6.  
  7. Disconnect and plug the fuel lines from the TBI unit.
  8.  
  9. Disconnect the accelerator cables from the TBI unit.
  10.  
  11. Disconnect the ignition wires from the spark plugs and the wires from the coil.
  12.  
  13. Remove the distributor cap with the wires.
  14.  
  15. Mark the location of the rotor to the distributor housing and the distributor housing to the intake manifold.
  16.  
  17. Remove the distributor hold-down clamp and the distributor.
  18.  
  19. Label and disconnect the EGR vacuum line and the emission hoses.
  20.  
  21. Remove the pipe brackets from the rocker arm covers.
  22.  
  23. Remove the rocker arm covers.
  24.  
  25. Remove the upper radiator hose and the heater hose.
  26.  
  27. Disconnect the electrical connectors from the coolant sensors.
  28.  
  29. Remove the intake manifold nuts/bolts, the manifold and gaskets.
  30.  
  31. Clean the gasket mounting surfaces.
  32.  

To install:
  1. Using RTV sealant, apply a 1 / 8 in. (3mm) bead to the front and rear of the block; make sure no water or oil is present.
  2.  
  3. Using new gaskets, marked right and left side, apply a 1 / 4 in. (6mm) bead of sealant to hold them in place and install them onto the cylinder heads; the gaskets may have to be cut to be installed around the pushrods.
  4.  
  5. Install the intake manifold and torque the nuts/bolts, in sequence, to 19 ft. lbs. (26 Nm) and retorque using the same sequence.
  6.  

Make sure the areas between the case ridges and the intake manifold are completely sealed.

  1. Install the heater and radiator hose to the manifold.
  2.  
  3. Using new gaskets, install the rocker arm covers.
  4.  
  5. Connect the electrical connectors to the coolant sensor.
  6.  
  7. Install the pipe brackets.
  8.  
  9. Align the matchmarks and install the distributor and the distributor cap.
  10.  
  11. Connect the fuel lines and the accelerator cables to the TBI unit.
  12.  
  13. Connect all the wires and vacuum hoses.
  14.  
  15. Install the air cleaner. Connect the negative battery cable. Refill the cooling system.
  16.  

3.2L Engine
1993-95 VEHICLES

See Figure 12



Click image to see an enlarged view

Fig. Fig. 12: Intake manifold removal sequence-1993-95 3.2L engine


CAUTION
Fuel injection systems remain under pressure even after the engine has been turned off. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and personal injury.

  1. Relieve the fuel pressure:
    1. Remove the fuel filler cap.
    2.  
    3. Remove the fuel pump relay from the underhood relay box.
    4.  
    5. Start the engine and let it run until it stalls. Then, crank the engine for an additional 30 seconds.
    6.  
    7. Turn the ignition switch to the OFF position.
    8.  

  2.  
  3. Disconnect the negative battery cable. Reinstall the fuel pump relay.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Disconnect the accelerator pedal cable from the throttle body and bracket.
  8.  
  9. Disconnect the charcoal canister vacuum hose from the vacuum pipe.
  10.  
  11. Disconnect the air vacuum hose and the vacuum booster hose from the common chamber.
  12.  
  13. Disconnect the following electrical connectors:
    1. MAP sensor
    2.  
    3. Charcoal canister vacuum switching valve (VSV)
    4.  
    5. Exhaust Gas Recirculation VSV
    6.  
    7. Intake Air Temperature sensor
    8.  
    9. Engine ground cable
    10.  
    11. Fuel injector connectors
    12.  
    13. Thermo sensor connector
    14.  

  14.  
  15. Tag and then disconnect the spark plug wires.
  16.  
  17. Remove the ignition module assembly with the spark plug wires attached.
  18.  
  19. Tag and then disconnect the vacuum hoses from the throttle body.
  20.  
  21. Remove the four throttle body mounting bolts. Then, remove the throttle body.
  22.  
  23. Disconnect the PCV hose from the common chamber.
  24.  
  25. Disconnect the fuel pressure control valve vacuum hose from the common chamber.
  26.  
  27. Disconnect the Evaporative Emission Canister Purge hose from the common chamber.
  28.  
  29. Remove the EGR valve assembly from the common chamber.
  30.  
  31. Remove the common chamber (six bolts, two nuts, and three brackets).
  32.  
  33. Disconnect the fuel feed and return hoses from the fuel rail. Remove the bracket mounting bolts from the cylinder head cover.
  34.  
  35. Remove the two bolts and four nuts to remove the intake manifold from the engine.
  36.  

To install:

Use new self-locking nuts when installing the intake manifold. Use new manifold gaskets. Use new sealing washers when reconnecting the fuel lines.

  1. Install the intake manifold on the engine. Torque the bolts and nuts to 17 ft. lbs. (24 Nm). Tighten the bolts from the center towards the ends.
  2.  
  3. Connect the electrical connectors to the fuel injectors and the thermo sensor.
  4.  
  5. Connect the fuel return and feed hoses to the fuel rail.
  6.  
  7. Install the common chamber. Torque the bolts and nuts to 17 ft. lbs. (24 Nm).
  8.  
  9. Install the EGR assembly. Torque the bolts to 78 inch lbs. (9 Nm).
  10.  
  11. Connect the charcoal canister purge and fuel pressure regulator vacuum hoses to the common chamber.
  12.  
  13. Connect the PCV hose to the common chamber.
  14.  
  15. Install the throttle body assembly and connect the vacuum hoses to the throttle body. Torque the throttle body mounting bolts to 16 ft. lbs. (22 Nm).
  16.  
  17. Install the ignition module assembly. Torque the mounting bolts to 16 ft. lbs. (22 Nm).
  18.  
  19. Reconnect the spark plug wires.
  20.  
  21. Reconnect the following electrical connectors:
    1. MAP sensor
    2.  
    3. Charcoal canister vacuum switching valve (VSV)
    4.  
    5. Exhaust Gas Recirculation VSV
    6.  
    7. Intake Air Temperature sensor
    8.  
    9. Engine ground cable
    10.  

  22.  
  23. Connect the air vacuum hose and the vacuum booster hose to the common chamber.
  24.  
  25. Connect the charcoal canister vacuum hose to the vacuum pipe.
  26.  
  27. Connect the accelerator cable to the throttle body and bracket. Adjust the cable so that the linkage rests against the stop when moved by hand.
  28.  
  29. Install the air cleaner assembly.
  30.  
  31. Verify that all electrical connectors and vacuum lines have been reconnected.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Turn the ignition key to the ON position for two seconds, then off. Turn the ignition ON again to pressurize the fuel system and check for leaks.
  36.  

1996 VEHICLES

See Figures 13, 14, 15, 16, 17, 18 and 19



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Fig. Fig. 13: Disconnecting the linear EGR valve-1996 3.2L engine



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Fig. Fig. 14: Intake manifold chamber bolts and bracket locations-1996 3.2L engine



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Fig. Fig. 15: Fuel feed and return lines-1996 3.2L engine



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Fig. Fig. 16: Fuel rail mounting (bottom) and the retaining bolts (top)-1996 3.2L engine



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Fig. Fig. 17: Fuel rail spacer grommets must be installed in the correct position-1996 3.2L engine



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Fig. Fig. 18: Lower intake manifold nut and bolt locations-1996 3.2L engine



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Fig. Fig. 19: Lower intake manifold chamber gaskets position-1996 3.2L engine

  1. Relieve the fuel system pressure:
    1. Remove the fuel filler cap.
    2.  
    3. Remove the fuel pump relay from the underhood relay box.
    4.  
    5. Start the engine and let it run until it stalls. Then, crank the engine for an additional 30 seconds.
    6.  
    7. Turn the ignition switch to the OFF position.
    8.  

  2.  
  3. Disconnect the negative battery cable and reinstall the fuel pump relay.
  4.  
  5. Remove the air cleaner and air intake duct.
  6.  
  7. Drain the engine coolant to a level below the upper radiator hose. Catch the coolant in a clean drain pan if it is to be reused.
  8.  
  9. Disconnect the throttle cable from the throttle body linkage.
  10.  
  11. Label and disconnect the following vacuum hoses from the intake manifold chamber:
    1. PCV hose
    2.  
    3. EVAP canister vacuum hose
    4.  
    5. Brake booster hose
    6.  

  12.  
  13. Label and disconnect the following sensor connectors from the rear of the intake manifold chamber:
    1. Ignition control module connectors
    2.  
    3. Linear EGR valve
    4.  
    5. MAP sensor
    6.  
    7. EVAP purge valve
    8.  
    9. Throttle position sensor
    10.  
    11. Idle air control valve
    12.  
    13. Intake air temperature sensor
    14.  

  14.  
  15. Disconnect the EGR valve supply tube and bracket.
  16.  
  17. Remove the throttle body.
  18.  


WARNING
Don't use solvent of any type when cleaning the gasket mating surfaces of the throttle body and intake manifold. Solvent may damage the machined surfaces of these components. Be careful not to scratch the mating surfaces.

  1. Disconnect the MAP sensor tube, and then unbolt the MAP sensor bracket.
  2.  
  3. Unbolt the intake manifold chamber from its brackets which are located at its front and rear edges.
  4.  
  5. Loosen the six manifold mounting bolts and two nuts in a crisscross sequence.
  6.  
  7. Remove the bolts and nuts, and then lift the chamber off of the base of the intake manifold. Note the positions of the long and short bolts.
  8.  
  9. Cover the intake manifold with a sheet of plastic, or clean shop towels to keep out dirt and foreign objects.
  10.  
  11. Carefully clean any dirt from the fuel rail and fuel fittings.
  12.  


CAUTION
Fuel injection systems remain under pressure even after the engine has been turned off. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and personal injury.

  1. Disconnect the fuel feed and return lines from the front of the fuel rail. Clean up any spilled fuel.
  2.  
  3. Label and disconnect the fuel injector wiring harness.
  4.  
  5. Unbolt the fuel return line bracket from the front of the intake manifold.
  6.  
  7. Unbolt the fuel rail from the intake manifold.
  8.  
  9. Carefully lift the fuel rail and injectors off of the intake manifold as an assembly. Move the fuel rail out of the work are so it won't be damaged; then, clean up any spilled fuel.
  10.  
  11. Remove the fuel rail spacer grommets from the sides of the intake manifold. Replace the spacer grommets if they are cracked or ripped.
  12.  
  13. Loosen the intake manifold nuts and bolts in a crisscross sequence working from the outer edges of the manifold toward the center.
  14.  
  15. Push the engine wiring harnesses aside and lift the intake manifold up and off of the engine block.
  16.  
  17. Remove the intake manifold gaskets. Be careful not to drop any pieces of the gaskets into the engine. Don't scratch or gouge the machined aluminum mating surfaces of the intake manifold and engine block.
  18.  
  19. Cover the intake openings with a sheet of plastic or clean shop towels to keep out dirt and foreign objects.
  20.  

To install:
  1. Remove the covers from the intake openings. Install new intake manifold gaskets.
  2.  
  3. Fit the intake manifold into position. Move the wiring harness back into position.
  4.  
  5. Install the intake manifold nuts and bolts. Tighten them in a two-step crisscross pattern to 15 ft. lbs. (20.5 Nm) working from the center of the manifold toward the outer edges.
  6.  
  7. Install the fuel rail spacer grommets.
  8.  
  9. Install the fuel rail assembly onto the intake manifold. Make sure all the fuel injectors are properly seated. Tighten the fuel rail bolts to 62 inch lbs. (7 Nm).
  10.  
  11. Reconnect the fuel feed and return lines. Install the return line bracket bolt.
  12.  
  13. Reconnect the fuel injector wiring harness.
  14.  
  15. Install a new intake manifold chamber gasket. Install the intake manifold chamber.
  16.  
  17. Install the six intake manifold chamber bolts and two nuts. Tighten the nuts and bolts to 15 ft. lbs. (20.5 Nm) in a crisscross sequence.
  18.  
  19. Install the intake manifold chamber bracket bolts.
  20.  
  21. Reconnect the MAP sensor tube and bracket.
  22.  
  23. Reconnect the EGR supply tube and bracket.
  24.  
  25. Install the throttle body with a new gasket. Tighten the bolts to 10 ft. lbs. (13.5 Nm) in a crisscross sequence.
  26.  
  27. Reconnect the following sensor connectors to the rear of the intake manifold chamber:
    1. Ignition control module connectors
    2.  
    3. Linear EGR valve
    4.  
    5. MAP sensor
    6.  
    7. EVAP purge valve
    8.  
    9. Throttle position sensor
    10.  
    11. Idle air control valve
    12.  
    13. Intake air temperature sensor
    14.  

  28.  
  29. Reconnect the following vacuum hoses to the intake manifold chamber:
    1. PCV hose
    2.  
    3. EVAP canister vacuum hose
    4.  
    5. Brake booster hose
    6.  

  30.  
  31. Reconnect the throttle cable to the throttle body linkage.
  32.  
  33. Install the air cleaner and air intake duct.
  34.  
  35. Reconnect the negative battery cable.
  36.  
  37. Refill and bleed the cooling system.
  38.  
  39. Crank the engine until it starts. Air trapped in the fuel lines may cause the engine to crank for a longer period of time than normal.
  40.  
  41. Check the fuel lines, fuel rail, and injectors for any signs of leakage.
  42.  
  43. Warm the engine up to normal operating temperature and check the operation of the throttle cable and linkage. Adjust if necessary.
  44.  
  45. Check the manifold and throttle body mating surfaces for vacuum leaks.
  46.  

 
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