Upper Intake Manifold Replacement

Intake Manifold Replacement - Upper

Removal Procedure





1. Disconnect the battery ground (negative) cable.
2. Disconnect the vacuum hose connection from the throttle body air inlet duct.
3. Disconnect the wiring harness connection from the intake air temperature (IAT) sensor in the throttle body air inlet duct.
4. Remove the throttle body air inlet duct.
5. Drain the engine coolant from the cooling system.
6. Remove the accelerator control and cruise control cables with bracket from the throttle body.
7. Disconnect the wiring harness connectors from the throttle body.
- Throttle position (TP) sensor
- Idle air control (IAC) valve
8. Disconnect the (left) front spark plug wires.
9. Disconnect the wiring harness attachment clips.
- Camshaft position (CMP) sensor wiring harness
- Left spark plug wire harness
- Engine wiring harness
10. Disconnect the thermostat bypass pipe coolant hoses from the throttle body.
11. Remove the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid.
12. Disconnect the vacuum hose at the manifold air pressure (MAP) sensor and upper intake manifold.
13. Remove the manifold air pressure (MAP) sensor and the bracket.





14. Disconnect the emission control vacuum harness.
15. Disconnect the vacuum hose connections from the upper intake manifold.
- Vacuum booster hose
- Automatic transaxle vacuum modulator hose
- Heater and air conditioning vacuum source hose
- Fuel pressure regulator
16. Remove the generator brace.





17. Remove the exhaust gas recirculation (EGR) valve.





18. Remove the right upper intake manifold bolts and studs.





19. Remove the left upper intake manifold bolts.
20. Remove the upper intake manifold.





21. Remove the upper intake manifold gasket.





22. If replacing the upper intake manifold, remove the throttle body.
23. Clean the seal surfaces on the manifold with degreaser.

Installation Procedure





1. If removed, install the throttle body.





2. Install the upper intake manifold gasket.





3. Install the upper intake manifold.
4. Loosely install the left upper intake manifold bolts.





5. Loosely install the right upper intake manifold bolts and studs.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the upper intake manifold bolts and studs.
- Tighten the upper intake manifold bolts and studs to 25 Nm (18 ft. lbs.).





7. Install the exhaust gas recirculation (EGR) valve.
8. Install the generator brace.
9. Connect the vacuum hose connections to the upper intake manifold.
- Vacuum booster hose
- Automatic transaxle vacuum modulator hose
- Heater and air conditioning vacuum source hose
- Fuel pressure regulator





10. Connect the emission control vacuum harness.
11. Install the manifold air pressure (MAP) sensor and bracket.





12. Connect the vacuum hose at the manifold air pressure (MAP) sensor and the upper intake manifold.
13. Install the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid.
14. Connect the thermostat bypass pipe coolant hoses to the throttle body.
15. Connect the wiring harness attachment clips.
- Camshaft position (CMP) sensor wiring harness
- Left spark plug wire harness
- Engine wiring harness
16. Connect the left spark plug wires.
17. Connect the wiring harness connectors to the throttle body.
- Throttle position (TP) sensor
- Idle air control (IAC) valve
18. Install the accelerator control and cruise control cables with bracket to the throttle body.
19. Fill the cooling system with engine coolant.
20. Install the throttle body air inlet duct.
21. Connect the wiring harness connection to the intake air temperature (IAT) sensor in the throttle body air inlet duct.
22. Connect the vacuum hose connection to the throttle body air inlet duct.
23. Connect the battery ground (negative) cable.