Remove or disconnect the following:
Negative battery cable and remove the air cleaner resonator.
Three vacuum hoses from the throttle body
Throttle cable support bracket and the throttle body assembly
Upper fan shroud and disconnect the vacuum brake booster hose, if necessary
Exhaust Gas Recirculation (EGR) pipe-to-manifold bolts and the EGR pipe-to-EGR adapter bolt, and the EGR pipe.
Idle Air Control (IAC) motor connector
Idle Air Control (IAC) motor
Manifold Absolute Pressure (MAP) sensor connector
Throttle Position (TP) sensor connector
Fuel injector harness connector
Right fender wheelhouse extension
Retainers from the engine harness bracket, the transmission filler tube (if equipped) and the fuel system evaporator pipe
Fuel pipes from the fuel rail
Accelerator cable and if equipped, the cruise control cable
Spark plug wires from the plugs
Spark plug wire harness retainer from the heater hose pipe and set aside the harness
Alternator rear brace by accessing the retaining nuts and bolts through the wheelhouse, if necessary
Engine wiring harness bracket located at the rear of the cylinder head (if necessary), by unfastening the bracket-to-valve cover and bracket-to-cylinder head retainers, then slide the bracket off the bolt at the rear of the cylinder head
Intake manifold bolts
Fuel rail bracket
Intake manifold and gasket
Typical intake manifold mounting—2.2L engine shown
Carefully remove all traces of gasket material from the mating surfaces. Check the EGR passage to be sure it is free of excessive carbon deposits and clean, as necessary.
Install or connect the following:
Lower intake manifold using a new gasket, then tighten the retaining bolts to 17 ft. lbs. (24 Nm) using the sequence illustrated
Intake manifold bolt tightening sequence—2.2L engine
Engine wiring harness bracket, if removed. Tighten the bracket-to-valve cover bolts to 88 inch lbs. (10 Nm) and the bracket-to-cylinder head bolt to 18 ft. lbs. (25 Nm).
Generator rear brace, if removed. Tighten the nuts and bolts to 18 ft. lbs. (25 Nm).
Spark plug wire harness and retainer and attach the spark plug wires to the plugs
Throttle body assembly, if removed and the throttle cable support bracket
Three vacuum lines to the throttle body
Retainers to the engine harness bracket, the transmission filler tube (if equipped) and the fuel system evaporator pipe
IAC motor connector
MAP sensor connector
TP sensor connector
EGR adapter and tighten the retainers to 97 inch lbs. (11 Nm)
EGR pipe to the EGR adapter and tighten the bolt to 18 ft. lbs. (25 Nm)
EGR pipe-to-intake manifold bolts and tighten the bolts to 89 inch lbs. (10 Nm)
Upper fan shroud and the brake booster hose
Air cleaner resonator and connect the negative battery cable.
Start the engine and check for leaks.
Properly relieve the fuel system pressure.
Disconnect the negative battery cable.
Remove the pressure regulator vacuum hose.
Remove the pressure regulator attaching screw.
Remove the pressure regulator assembly and the O-ring. Discard the O-ring.
Fuel pressure regulator location on fuel rail assembly—2.2L engine
Lubricate the new pressure regulator O-ring (3) with clean engine oil, then install the O-rings on the pressure regulator.
Install the pressure regulator assembly (2) onto the fuel rail (4).
Install the pressure regulator attaching screw (1) coated with an appropriate thread-locking material. Tighten the pressure regulator attaching screw to 106 inch lbs. (12 Nm).
Connect the negative battery cable.
Inspect for fuel leaks.
Turn ON the ignition, with the engine OFF for 2 seconds.
Turn OFF the ignition for 10 seconds.
Turn ON the ignition, with the engine OFF.