For 1990-2009 cars

### Removal Procedure

1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.

Warning: Refer to Battery Disconnect Warning in the Preface section.

3. Disconnect the negative battery cable.
4. Disconnect the engine control module (ECM) ground terminal from the intake manifold.

Warning: Refer to Safety Glasses Warning in the Preface section.

5. Drain the engine coolant. Refer to Cooling System Draining and Filling.
6. Remove the engine cover and throttle body. Refer to Throttle Body Assembly Replacement.
7. Disconnect the intake manifold pressure sensor connector, attaching bolt, and vacuum hose.
8. Disconnect the intake air temperature (IAT) sensor connector and remove the IAT sensor.
9. Remove the intake manifold upper bracket
10. Remove the fuel rail bolts and the fuel rail.
11. Remove the all the vacuum hoses from the intake manifold including the positive crankcase ventilation (PCV) hose and brake booster vacuum hose.
12. Remove the exhaust gas recirculation (EGR) pipe.
13. Remove the intake manifold upper bracket bolts.
14. Remove the intake manifold upper bracket.
15. Remove the fuel rail bolts.
16. Remove the fuel rail.
17. Remove the alternator. Refer to Generator Replacement l.
18. Remove the intake manifold support bracket.
19. Remove the intake manifold retaining bolts/nuts in the sequence shown.
20. Remove the intake manifold and gasket.
21. Clean the sealing surfaces of the intake manifold and the cylinder head.

### Installation Procedure

Caution: Refer to Fastener Caution in the Preface section.

1. Install the fuel rail.

Tighten
Tighten the fuel rail bolts to 25 N·m (18 lb ft).

2. Install the new intake manifold gasket and intake manifold.

Tighten
Tighten the intake manifold bolts and nuts to 25 N·m (18 lb ft).

3. Install the EGR pipe.

Tighten
Tighten the EGR pipe bolts to 10 N·m (89 lb ft).

4. Install the intake manifold support bracket.

Tighten

• | Tighten the intake manifold support bracket upper bolts to 25 N·m (18 lb ft).

• | Tighten the lower bolts to 45 N·m (33 lb ft).

5. Install the alternator. Refer to Generator Replacement.
6. Install the fuel rail.
7. Install the fuel rail bolts.

Tighten
Tighten the fuel rail bolts to 25 N·m (18 lb ft).

8. Install the intake manifold upper bracket.
9. Install the intake manifold upper bracket bolts.

Tighten
Tighten the intake manifold upper bracket bolts to 25 N·m (18 lb ft).

10. Install the IAT and connect the IAT sensor connector.
11. Install the intake manifold pressure sensor and vacuum hose.
12. Install the throttle body and engine cover. Refer to Throttle Body Assembly Replacement
13. Refill the engine cooling system. Refer to Cooling System Draining and Filling.
14. Install the fuel pump fuse and connect the negative battery cable.