Upper Intake Manifold Replacement

TOOL REQUIRED
^ J28467-360 Engine Support Fixture

REMOVAL
1. Disconnect the negative battery cable.
2. Depressurize the fuel system. See Powertrain Management.
3. Remove the top half of the air cleaner assembly.
4. Drain and recover the cooling system. See Cooling System.





5. Remove the EGR pipe from the exhaust manifold. See Exhaust System.
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. See Starting and Charging.





10. Remove the secondary ignition wires from the spark plugs.
11. Remove the secondary ignition wires from the harness at the plenum.
12. Remove the following components at the same time:
^ Electronic ignition coil and module assembly
^ EVAP canister purge solenoid
13. 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
14. Remove the following vacuum lines:
^ Vacuum Modulator
^ Fuel Pressure Regulator
^ PCV
15. Remove the MAP sensor from the upper intake manifold.





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

INSTALLATION
1. Install the upper intake manifold.

Notice: The OEM service manual does not provide a torque sequence for the upper intake manifold.

2. Install the upper intake manifold bolts. 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:
^ TP sensor
^ IAC
^ Injector harness
^ ECT sensor
^ MAP sensor
^ CMP sensor
6. Install the following components:
^ EVAP canister purge solenoid
^ Electronic ignition coil and module assembly
7. Install the generator. See Starting and Charging.
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. See Cooling System.
18. Connect the negative battery cable.
19. Inspect for proper fluid levels.
20. Check for leaks.