Check that the battery is fully charged.
Start the engine and allow it to reach normal operating temperature.
Turn the engine off and wait about 10minutes to allow the exhaust manifold to cool.
Remove the spark plugs and inspect. Refer to Spark Plug.
Connect a compression gauge to the No. 1 spark plug hole.
Starting with the compression gauge at zero, fully depress the accelerator pedal and crank the engine for about 10 seconds.
Record the maximum gauge reading.
Check the compression at each cylinder.
The maximum difference in compression between cylinders should be 26 psi(196kPa).
Normal compression : 164psi(1,128kPa)
Minimum compression : 114psi(790kPa)
If the compression in one or more cylinders is low, pour a small amount(about one tablespoon) of engine oil into the cylinder and recheck the compression.
If the compression increases, the piston, the piston rings or the cylinder wall may be worn.
If the compression remains low, a valve may be stuck or seated improperly.
If the compression in adjacent cylinders remains head gasket may be defective or the cylinder head distorted.
Re-install the spark plugs, refer to Spark Plug Installation.
Loosen the clamps on the air intake hose.
Remove the intake hose between the mass air flow sensor and the air funnel.
Remove the four smaller hoses joining the air funel.
Remove the two mounting bolts for the air funnel.
Loosen the clamp at the intake elbow and remove the air funnel.
Remove the clamps from the air funnel and mass air flow sensor ends of the air intake hose.
Remove the air intake hose.
Loosen the clamps at the mass air flow sensor and the air cleaner housing ends of the air intake duct.
Remove the two mounting bolts for the air flow sensor.
Remove the clamps and air intake duct.
Remove the two bolts at the front of the fresh air duct.
Loosen the clamp between the air duct and the air cleaner housing.
Removal (DTNAMIC CHAMBER)
Remove the two bolts for the air intake hose.
Loosen the clamp at the throttle body intake hose.
Remove the four breather hoses from the intake duct at the throttle body.
Disconnect the electrical connector at the mass air flow sensor.
Loosen the air intake hose clamp at the air cleaner assembly.
Remove the bolt for the air intake hose bracket.
Remove the bolts for the mass air flow sensor.
Remove the air intake hose assembly.
Remove the accelerator cable bracket bolts.
Disconnect the accelerator cable.
Drain the engine coolant.
Remove the vacuum hose for the brake booster.
Disconnect the throttle position sensor electrical connector.
Disconnect the two coolant hoses form the throttle body.
Remove the clamp and the idle speed controller air hose.
Remove the clamp and the air hose from the air rail.
Disconnect the PCV hose from the dynamic chamber.
Remove the vacuum line from the pressure regulator.
Remove the vacuum line from the EGR valve.
Disconnect the electrical connector from the EGR solenoid.
Remove the cruise control vacuum lines from the plenum chamber.
Disconnect the idle speed controller electrical connector.
Remove the two bolts and stay bracket from the plenum chamber.
Remove the top two bolts form the manifold bracket.
Raise the vehicle on a lift.
Remove the two bottom bolts with the manifold bracket.
Remove the heater inlet hose at the elbow.
Remove the vacuum line at the vacuum pipe.
Remove the three nuts and bolts from the plenum chamber assembly and remove the plenum chamber assembly.
Remove the vacuum hose from the top of the throttle body.
Remove the throttle body.
Remove the two bolts and nuts to remove the solenoid valve assembly and bracket.
Remove the two bolts with the idle speed activator and bracket.
Remove the two bolts and the tube assembly.
A hot exhaust system can produce a serious burn.
Remove one bolt from the bracket at the bottom of the header pipe.
Remove two nuts from the geat shield covering the upper end of the header pipe.
Remove three nuts that attach the header pipe to the catalytic converter.
Remove three nuts that attach the header pipe to the exhaust manifold.
Removal(Three―way Catalytic(TWC))
Do not touch the TWC converter heat shield when the engine is running. The conversion process produces high heat. Even when the engine is not running, it remains hot a long time. It will remain hot after the tail pipe has cooled. Touching the heat shield may produce a serious burn.
Remove the three nuts from the bottom flange of the header pipe.
Remove two nuts from the forward muffler flange.
Remove the TWC converter.
Removal(Exhaust System Support)
Lubricate the inside of the support around both shafts with silicone lubricant.
Pry both top and bottom of the support from its respective hangers.
Position the air funnel and install the two mounting bolts. Tighten the bolts.
Tighten the clamps at the intake elbow.
Install the four hoses joining the air funnel.
Install the air intake hose.
Tighten the two clamps for the air intake hose.
Position the air intake hose between the mass air flow sensor and the air funnel.
Install and tighten the clamps at each end of the hose.
Position the clamps on each end of the air intake duct.
Place the air intake duct between the air cleaner housing and the mass air flow sensor.
Slide the air intake duct over the lip on the mass air flow sensor and tighten the clamp.
Slide the air intake duct over the lip on the air cleaner housing and tighten the clamp.
Replace the two mass air flow sensor retaining bolts.
Position the fresh air duct onto the air cleaner housing inlet.
Be sure the clamp is OM the duct.
Install the two mounting bolts at the front sides of the air duct.
Tighten the clamp on the duct at the air cleaner housing.
Installation (DYNAMIC CHAMBER)
Clean the gasket surfaces of the throttle body and plenum chamber.
Install the solenoid valve assembly and bracket and tighten the two bolts and nuts.
Install the speed controller and tighten the two bolts.
Install the tube assembly and tighten the two bolts.
Position the gasket for the throttle body.
Install the throttle body and tighten the two nuts and bolts.
Install the gasket for the plenum chamber.
Install the plenum chamber.
Tighten the plenum chamber nuts and bolts.
Connect the PCV hose to the plenum chamber.
Install the air hose to the air rail.
Install the idle air speed controller bracket.
Connect the idle speed controller electrical connector.
Install the heater inlet hose at the elbow.
Install the idle speed controller hose.
Install the cruise control vacuum line to the plenum chamber.
Install the brake booster vacuum line to the plenum chamber.
Connect the vacuum hose to the fuel pressure regulator.
Connect the electrical connector to the EGR solenoid.
Connect the vacuum hose to the EGR valve.
Install the top two bolts to the manifold bracket. Do not fully tighten the bolts.
Raise the vehicle on a lift.
Install and tighten the bottom two bolts for the manifold bracket.
Tighten the top two bolts for the manifold bracket.
Connect the two coolant hoses to the throttle body.
Connect the throttle position sensor electrical connector.
Connect the vacuum hose to the vacuum pipe.
Install the air intake hose assembly.
Install and tighten the bolt for the air intake hose bracket.
Install and tighten the bolts for the mass air flow sensor.
Connect the mass air flow sensor electrical connector.
Tighten the air intake hose clamp at the air cleaner.
Tighten the air intake hose clamp at the throttle body.
Connect the accelerator cable.
Install and tighten the accelerator cable bracket bolts.
Free play for accelerator cable should be 0.120 inch (3.0 mm)
Install and tighten the two bolts for the air intake hose assembly.
Install the four breather hoses into the air intake assembly.
Start the engine and check for leaks.
Dynamic Chamber Support Brackets
Install the dynamic chamber support brackets at the front and rear of the intake manifold.
Tightening torque : 14-19 ft·lb(19-25N·m)
Installation(Header Pipe)
Clean mating surfaces as required.
Position header pipe for installation.
Install three nuts that attach the header pipe to the exhaust manifold.
Tghten these nuts to 70 lb·ft (100N·m)
Install two nuts that attach the header pipe to the catalytic converter.
Tighten these nuts to 70 lb·ft (100N·m)
Install one bolt to attach the bottom end of the header pipe to the bracket.
Tighten this bolt to 38 lb·ft (50N·m)
Position the heat shield at the upper end of the header pipe.
Install two nuts to secure heat shield.
Tighten these nuts to 7 lb·ft (10N·m)
Installation(Three―way Catalytic(TWC))
Clean mating surfaces as required.
Position the TWC converter for installation.
Tighten two nuts at the forward muffler flange
Tighten these two nuts to 70 lb-ft (100N·m)
Tighten three nuts at bottom flange of the header pipe.
Tighten these three nuts to 70 lb-ft (100N·m)
Installation(Exhaust System Support)
Lubricate both shafts with silicone lubricant.
Lubricate the inside of both holes of the support with silicone lubricant.
Install the support onto both hangers.
Check that the battery is fully charged.
Start the engine and allow it to reach normal operating temperature.
Turn the engine off and wait about 10minutes to allow the exhaust manifold to cool.
Remove the spark plugs and inspect. Refer to Spark Plug.
Connect a compression gauge to the No. 1 spark plug hole.
Starting with the compression gauge at zero, fully depress the accelerator pedal and crank the engine for about 10 seconds.
Record the maximum gauge reading.
Check the compression at each cylinder.
The maximum difference in compression between cylinders should be 26 psi(196kPa).
Normal compression : 164psi(1,128kPa)
Minimum compression : 114psi(790kPa)
If the compression in one or more cylinders is low, pour a small amount(about one tablespoon) of engine oil into the cylinder and recheck the compression.
If the compression increases, the piston, the piston rings or the cylinder wall may be worn.
If the compression remains low, a valve may be stuck or seated improperly.
If the compression in adjacent cylinders remains head gasket may be defective or the cylinder head distorted.
Re-install the spark plugs, refer to Spark Plug Installation.
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