Upper Intake Manifold Replacement

Removal Procedure

Tools Required

J 28467-360 Engine Support Fixture

1. Disconnect the negative battery cable.

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.

2. Depressurize the fuel system.
3. Remove the top half of the air cleaner assembly.
4. Drain and recover the cooling system.





5. Remove the EGR pipe from the exhaust manifold.
6. Remove the drive belt.
7. Remove the brake vacuum pipe at the plenum.
8. Remove the power steering lines at the generator bracket.
9. Remove the generator.





10. Remove the secondary ignition wires from the spark plugs.

Remove the secondary ignition wires from the harness at the plenum.

11. Next, remove the following components at the same time:
^ Electronic ignition coil and module assembly
^ EVAP canister purge solenoid

12. Remove the following upper engine wiring connectors:
^ Throttle Position (TP) sensor
^ IAC sensor
^ Injector harness
^ Engine Coolant Temperature (ECT) sensor
^ MAP sensor
^ Camshaft Position (CMP) sensor

13. Remove the following vacuum lines:
^ Vacuum Modulator
^ Fuel Pressure Regulator
^ PCV

14. Remove the MAP sensor from the upper intake manifold.





15. Remove the upper intake manifold bolts.
16. Remove the upper intake manifold.

Installation Procedure





1. Install the upper intake manifold.
2. Install the upper intake manifold bolts.

Tighten
Tighten the bolts to 25 Nm (18 lb ft).

3. Install the MAP sensor.
4. Connect the following vacuum lines:
^ Vacuum Modulator
^ Fuel Pressure Regulator
^ PCV

5. Install the following upper engine wiring connectors:
^ Throttle Position (TP) sensor
^ IAC
^ Injector harness
^ Engine Coolant Temperature (ECT) sensor
^ MAP sensor
^ Camshaft Position (CMP) sensor

6. Install the following components:
^ EVAP canister purge solenoid
^ Electronic ignition coil and module assembly

7. Install the generator.
8. Install the power steering line at the generator bracket.
9. Install the drive belt.





10. Install the secondary ignition wires to the spark plugs.
11. Install the secondary ignition wires to the harness at the plenum.





12. Install the EGR pipe to the exhaust manifold.
13. Install the following items to the throttle body:
^ Throttle body cable
^ Cruise control cable

14. Install the top half of the air cleaner assembly.
15. Install the brake vacuum pipe.
16. Install the cables to the throttle body.
17. Fill the cooling system.
18. Connect the negative battery cable.
19. Inspect for proper fluid levels.
20. Check for leaks.