'00-'02 SOHC Intake Manifold Gasket Replacement How-to

[RC1488]

Description:
The following are instructions for how to change the intake manifold gasket on a 3rd generation SOHC S-series.

Tools needed:


10mm Deep dish socket
13mm Deep dish socket
13mm wrench
14mm wrench (Not Shown)
3/8 ratchet
Coolant (optional) (Not shown)
Jack and jack stands or other device to raise the car (Not shown)

Materials Needed:
Intake Manifold gasket (I got mine from Rockauto.com)

Time: (From car first into garage to exiting the garage): 3.5 hours

Common Symptoms of a bad intake gasket:
p0301
p0507
p0410

Verification of bad intake gasket:
Idle changed when brake cleaner was sprayed around gasket.

Safety:
1) Always wear gloves. Rubber gloves are ok, but mechanics gloves are preferred.
2) Wear safety glasses when under neath the car. Coolant is VERY harmful if it gets in your eyes. Coolant runs through the manifold will leak slightly as you remove the nuts.
3) Make sure Engine is cold

Procedure:
1. Spray PB Blaster around all Intake Manifold bolts.

2. Remove the air deflector (optional). Makes #3 easier.

3. Drain the coolant. Coolant runs through the intake manifold so the coolant must be drained. There are two places to drain it from: the bottom passenger side of the radiator or the bolt on the water pump. See the How-to Library for instructions. May be a good time to replace thermostat and ECTS. You can either replace the coolant or save it and put it back into the car once you are finished with the operation.

4. Remove plastic tube from throttle body to Air box

5. Disconnect EGR Connector

6. Remove PCV and any hoses connected to plastic tub in #4

4. Remove nuts holding manifold to the head. Be careful to catch them as there are quite a few crevices they can land in and get stuck (trust me)

Top) The wrench pictured under Tools Needed is perfect for this job. You can use it to remove the top row of nuts with no issues. See below:


The wrench fits nicely between the throttle cable bracket so it does not have to be disconnected or removed

Bottom) The bottom row can be accessed easiest from underneath the car. Wear your goggles. They can be accessed from the top of the car with the 6' 3/8 extension however.

The bottom bolt on the driver side is BEST accessed from the top. A 3/8 extension with the deep dish socket allows the the ratchet to fit snugly behind the EGR. You can use your fingers going under neath the EGR to guide the socket over the nut.


This is the bottom drivers side bolt. This bolt is hidden from view from either orientation. The socket by itself lets the ratchet fit perfect.

8) Remove the fuel hose bracket
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9) Remove the drive belt. 14mm wrench is needed (See Richpin's Videos for how)

10) Remove (2) 10mm bolts from Power Steering pump. The pump blocks the manifold from being pulled out enough. The 2 Bolts ONLY. They are located at 2 o'Clock and 4 o'clock positions. You do NOT need to remove the pump, just allow it to rotate upon the bottom bolt. Using a screw driver push the pump away from the head towards the fire wall. (From Richpins video its 4:22 to 6:57)


Notice pump in the way of the manifold. Also Notice the wrinkle in the gasket

11) Pull the Intake Manifold away from head. You are NOT removing it from the bay. You just want it past the bolts enough to pull the old gasket it out. A screw driver here to hold the manifold away as you pull the gasket out is needed

13) Remove gasket

14) Inspect the old gasket and the mating surfaces of the head and the manifold making sure they are clean. Carb cleaner is always helpful.


Notice there is a piece missing from the old gasket at the bottom right. Its VITAL there is none of the old gasket left on the head or manifold. Or the new gasket can leak and youll be doing this again

Installation:
-Reverse above directions. Be CAREFUL when installing the new gasket. Take your time and do it right. It is quite fragile and can bend or rip.

-I torqued by the manifold nuts to 22ft/lbs. I do NOT have a manual for the third gen however based off past generations this torque did not change

-Sequence:
8415 Top
73269 Bottom

-Do not forget to refill your coolant after you tighten the drain plugs.

-If you have any DTC codes, reset the PCM with a scanner or remove the PCM B fuse for 1 min

As always post any questions during the operation in the forum for almost equivelant on site advice

Goodluck!