For 1990-2009 cars

### Removal Procedures

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Release the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls.
3. Remove the fuel filter cap in order to release the fuel vapor pressure in the fuel tank. After releasing the pressure, replace the cap.
4. Remove the air intake pipe from the ACL intake hose and throttle hose. Refer to Air Intake Pipe Replacement.
5. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
6. Remove the three bolts and the throttle cover from the intake manifold (4).
7. Disconnect the accelerator cable (3) and kickdown cable (4) (automatic transmission equipped vehicles) from the throttle body bellcrank (1).
8. Remove the following from the throttle body:

• | One bolt

• | One nut

• | One screw

• | The accelerator cable bracket (2)

9. Disconnect the following electrical connectors:

• | Throttle Position (TP) Sensor

• | Idle Air Control (IAC) Valve

• | Engine Coolant Temperature (ECT) Sensor (4)

• | ECT sensor sending unit

• | A/C ECT switch (3) (A/C equipped vehicles only)

• | Evaporative emission canister purge valve

• | Exhaust Gas Recirculation (EGR) temperature sensor

• | EGR solenoid vacuum valve

• | EGR by-pass valve

• | Fuel injectors

• | Wiring harness from retaining clamps

• | Engine ground wire (7) from intake surge tank

10. Remove the following vacuum hoses:

• | EVAP canister purge valve

• | Vacuum modulator supply hose (automatic transmission equipped vehicles)

• | Brake booster supply hose

• | EGR valve

• | EGR pressure transducer

• | Manifold Absolute Pressure (MAP) Sensor hose from the sensor

11. Remove the coolant hose from the IAC valve.
12. Remove the IAC air hose from the IAC valve.
13. Remove the coolant hoses from the fast idle air valve below the throttle body.
14. Disconnect the fuel feed hose at the fuel feed hose union (1).
15. Disconnect the fuel return hose from the fuel return line.
16. Remove the PCV hose from the PCV valve.
17. Loosen the upper radiator hose from the thermostat housing. Remove the upper radiator hose from the thermostat housing.
18. Remove the coolant bypass hose from the intake manifold.
19. Remove the following from the intake manifold:

• | One bolt

• | One nut

• | The generator adjusting arm bracket (1)

20. Remove the two bolts and the front intake manifold reinforcement bracket (2) from the intake manifold.
21. Remove the two bolts and the rear intake manifold reinforcement bracket (1) from the intake manifold.
22. Remove the two bolts and the lower intake manifold support bracket (3) from the intake manifold.
23. Remove the following from the cylinder head:

• | Eight nuts

• | Three bolts

• | The intake manifold with the gasket

• | The intake surge tank

• | The throttle body

24. Remove the following from the intake manifold if required:

• | The PCV valve

• | The EGR valve

• | The ECT sensor (4)

• | The ECT sensor sending unit

• | The A/C ECT switch (3) (A/C equipped vehicles)

• | The EGR temperature sensor

### Installation Procedure

1. Install the following to the intake manifold if required:

• | The PCV valve

• | The EGR valve

• | The ECT sensor (4)

• | The ECT sensor sending unit

• | The A/C ECT switch (3) (A/C equipped vehicles)

• | The EGR temperature sensor

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install a new intake manifold gasket (3) and the intake manifold (4) with intake surge tank (1) and throttle body (2) to the cylinder head. Secure with eight nuts and three bolts.

Tighten
Tighten the intake manifold nuts and bolts to 23 N·m (17 lb ft).

3. Install the lower intake manifold support bracket (3) to the intake manifold. Secure the bracket with two bolts.

Tighten
Tighten the lower intake manifold support bracket bolts to 50 N·m (37 lb ft).

4. Install the rear intake manifold reinforcement bracket (1) to the intake manifold. Secure the bracket with two bolts.

Tighten
Tighten the rear intake manifold support bracket bolts to 50 N·m (37 lb ft).

5. Install the front intake manifold reinforcement bracket (2) to the intake manifold. Secure the bracket with two bolts.

Tighten
Tighten the front intake manifold support bracket bolts to 50 N·m (37 lb ft).

6. Install the generator adjusting arm bracket (1) to the intake manifold. Secure the bracket with one bolt and one nut.

Tighten
Tighten the generator adjusting arm bracket nut bolt to 50 N·m (37 lb ft).

7. Connect the coolant bypass hose to the intake manifold.
8. Install the upper radiator hose to the thermostat housing.
9. Tighten the upper radiator hose clamp at the thermostat housing.
10. Connect the PCV to the PCV valve.
11. Install the fuel return hose.
12. Install the fuel feed hose at the fuel feed hose union (2).
13. Install the coolant hoses to the fast idle air valve below the throttle body.
14. Install the IAC air hose to the IAC valve.
15. Install the coolant hose to the IAC valve.

Install the following vacuum hoses:

• | EGR pressure transducer

• | EGR valve

• | Brake booster supply hose

• | Vacuum modulator supply hose (automatic transmission equipped vehicles)

• | EVAP canister purge valve

• | Manifold Absolute Pressure (MAP) Sensor hose from the sensor

16. Install the following connectors:

• | Engine ground wire (7) from intake surge tank

• | Wiring harness from retaining clamps

• | Fuel injectors

• | EGR solenoid vacuum valve (1)

• | EGR by-pass valve

• | EGR temperature sensor

• | Evaporative emission canister purge valve

• | A/C ECT switch (3) (A/C equipped vehicles only)

• | ECT sensor sending unit

• | Engine Coolant Temperature (ECT) Sensor (4)

• | Idle Air Control (IAC) Valve

• | Throttle Position (TP) Sensor

17. Install the accelerator cable (3) and kickdown cable (4) (automatic transmission equipped vehicles) to the throttle body bellcrank (1).

• | Adjust the accelerator cable as necessary. Refer to Accelerator Control Cable Replacement in Engine Controls.

• | Adjust the kickdown cable (automatic transmission equipped vehicles) as necessary. Refer to Automatic Transmission.

18. Install the throttle cover to the intake manifold (2). Secure the cover with three bolts.

Tighten
Tighten the throttle cover bolts to 15 N·m (11 lb ft).

19. Refill the cooling system as necessary. Refer to Cooling System Draining and Filling in Engine Cooling.
20. Install the air intake pipe to the throttle body hose and the ACL intake hose. Refer to Air Intake Pipe Replacement.
21. Connect the negative battery cable. Refer to Battery Replacement in Engine Electrical.