REMOVAL & INSTALLATION
See Figures 1 and 2
- Turn the ignition key to the OFF position. Disconnect the negative battery cable. Wait at least 90 seconds from the time the negative battery was disconnected to start work.
- Position a suitable drain pan under the radiator drain cock and drain the cooling system.
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable has been disconnected. The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative battery cable, the SRS may deploy. When the negative terminal cable is disconnected from the battery, memory of the clock and radio will be canceled. Before you start working, make a note of the contents memorized by the audio memory system. When you have finished working, reset the audio systems and adjust the clock. Never use a back-up power supply from outside the vehicle.
- Remove the accelerator cable return spring along with the cable and bracket from the throttle body.
- Loosen the clamp and disconnect the air cleaner hose.
- Disconnect the throttle position sensor harness.
Disconnect, label and plug the following hoses:
Two water by-pass hoses.
- Remove the bolts attaching the throttle body to the intake manifold. Remove the throttle body and gasket.
- Loosen the union nut of the EGR pipe. Remove the two bolts, EGR valve modulator and gasket. Remove the bolt and the EGR valve.
- Remove the intake manifold stays and on the No. 1 air intake chamber.
- Disconnect the vacuum sensing hose.
- Remove the two nuts and six bolts that attach the intake manifold to the cylinder head.
- Remove the bolt, vacuum hose bracket and the main engine wire harness. On California models, remove the wire bracket.
- Remove the intake manifold and gasket from the cylinder head.
- Thoroughly clean the intake manifold and cylinder head surfaces. Using a machinist's straight edge and a feeler gauge, check the surface of the intake manifold for warpage. If the warpage is greater than 0.0118 inch (0.300mm), replace the intake manifold.
- Place a new gasket onto the intake manifold and position the intake manifold onto the cylinder head with the proper amount of nuts and bolts. Tighten the nuts and bolts to 14 ft. lbs. (19 Nm).
- Install the intake manifold stays. Tighten the 12mm bolts to 14 ft. lbs. (19 Nm) and the 14mm bolts to 31 ft. lbs. (42 Nm).
- Place a new gasket onto the throttle body and attach the unit to the intake manifold with the four bolts. Uniformly tighten the bolts in several passes to 14 ft. lbs. (19 Nm).
- Install the EGR valve with new gasket and the modulator. Tighten the pipe union nut to 43 ft. lbs. (59 Nm) and the bolts to 9 ft. lbs. (13 Nm).
- Unplug and connect all hoses along with attaching any related wiring.
- Connect the throttle position sensor and ISC valve wiring.
- Connect the air cleaner hose and tighten the hose clamp.
- Attach the throttle cable with bracket onto the throttle body. Install the return spring.
- On vehicles equipped with automatic transaxle, connect the accelerator cable and adjust it.
- Fill the cooling system to the proper level and connect the negative battery cable.
- Start the engine and inspect for leaks.
See Figures 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 and 13
- Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
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.
- Drain the engine coolant into a suitable container.
- Disconnect the throttle body from the air intake chamber.
- Disconnect the ground strap harness.
- Tag and disconnect the hoses from the intake chamber.
- On vehicles with A/C remove the hose from the idle-up valve.
- On vehicles with P/S remove the air hose from the air pipe.
- Using a 6mm hexagon wrench, remove the 3 bolts, 2 nuts, and the air intake chamber cover and gasket.
- If equipped with EGR, remove the EGR VSV.
- Remove the intake manifold stay.
- Unbolt and remove the air pipe.
- The engine wiring harness attached to the cylinder head may need to be disconnected to access bolts for the intake manifold.
- Disconnect the fuel injector wiring.
- Remove the union bolt and two gaskets and disconnect the fuel inlet hose from the delivery pipe. Place a shop towel under the connection to absorb the fuel.
- Disconnect the fuel return hose from the fuel pressure regulator and the air hose from the IAC valve to the air pipe.
- Remove the two bolts and the delivery pipe together with the four injectors.
- Remove the 7 bolts, 4 nuts, ground strap, intake manifold and the two gaskets.
- Place a new intake manifold gasket to the cylinder head. Place a new EGR gasket to the cylinder head, with the protrusion facing down.
- Install the intake manifold with 7 bolts, 4 nuts, and the ground strap. Uniformly tighten the bolts and nuts in several passes. Tighten the A nuts to 9 ft. lbs. (13 Nm). Tighten all other nuts and bolts to 14 ft. lbs. (19 Nm).
- Install the injectors and the delivery pipe.
- If equipped with EGR, install the EGR VSV.
- Install the air intake chamber cover with a new gasket.
- Install the throttle body.
- Install the air pipe and fuel inlet hose with the two bolts and nut. Install new gaskets on the fuel inlet hose and secure the clamp of the inlet hose to the intake manifold.
- Connect the fuel return hose to the pressure regulator and the air hose from the IAC valve to the air pipe.
- Install the intake manifold stay. Tighten the 12mm head bolt to 14 ft. lbs. (19 Nm) and the 14mm head bolt to 29 ft. lbs. (39 Nm).
- Connect the hoses to the intake chamber.
- If equipped, install the air hoses the idle-up valve and the air pipe.
- Connect the ground strap connector and connect the fuel injector connectors.
- Refill the cooling system with coolant and connect the negative battery cable. Start the engine, check for leaks, and road test the vehicle for proper operation.