Upper Intake Manifold Replacement

Intake Manifold Replacement- Upper
Removal Procedure





1. Disconnect the negative battery cable.
2. Remove the air cleaner intake duct.
3. Remove the accelerator controls cable bracket with the accelerator control and the cruise control cables.
4. Remove the vacuum hoses from the following:
^ Fuel pressure regulator
^ Evaporative Emissions (EVAP) canister purge valve
^ Manifold vacuum source
^ Brake booster to the upper intake manifold
^ Windshield washer system
5. Disconnect the electrical connectors from the following:
^ Exhaust Gas Recirculation (EGR) valve
^ Mass Air Flow (MAF) sensor
^ Idle Air Control (IAC) valve
^ Throttle Position (T/P) sensor
^ Evaporative Emission (EVAP) canister purge valve
6. Drain the cooling system.
7. Remove the left side spark plug wires from the spark plugs.
8. Remove the following wiring harnesses from the retainers:
^ Camshaft Position (CMP) sensor wiring harness
^ Left side spark plug wire harness
^ Engine wiring harness





9. Remove the thermostat bypass pipe coolant hoses (3,4) from the throttle body.
10. Remove the ignition coil bracket with the coils.
11. Remove the EVAP canister purge valve.
12. Remove the Manifold Absolute Pressure (MAP) sensor and the bracket.
13. Remove the Exhaust Gas Recirculation (EGR) valve.





14. Remove the upper intake manifold bolts and the stud.
15. Remove the upper intake manifold.
16. Remove the upper intake manifold gaskets.





17. If replacing the upper intake manifold, remove the throttle body.
18. Clean the upper intake gasket mating surfaces.

Installation Procedure





1. If removed, install the throttle body.





2. Install the upper intake manifold gaskets.
3. Install the upper intake manifold.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the upper intake manifold bolts and the stud.
^ Tighten the bolts and the stud to 25 Nm (18 ft. lbs.).
5. Install the EGR valve.
6. Install the MAP sensor bracket and the sensor.
7. Install the EVAP canister purge valve.
8. Install the ignition coil bracket with the coils.





9. Install the thermostat bypass pipe coolant hoses (3, 4) to the throttle body.
10. Install the following wiring harnesses to the retainers:
^ Engine wiring harness
^ Left side spark plug wire harness
^ Camshaft Position (CMP) sensor wiring harness
11. Install the left side spark plug wires to the spark plugs.
12. Connect the electrical connectors to the following:
^ Evaporative Emission (EVAP) canister purge valve
^ Throttle Position (T/P) sensor
^ Idle Air Control (IAC) valve
^ Mass Air Flow (MAF) sensor
^ Exhaust Gas Recirculation (EGR) valve





13. Install the vacuum hoses to the following:
^ Windshield washer system
^ Brake booster to the upper intake manifold
^ Manifold vacuum source
^ Evaporative Emissions (EVAP) canister purge valve
^ Fuel pressure regulator
14. Install the accelerator controls cable bracket with the accelerator control and the cruise control cables.
15. Install the air cleaner intake duct.
16. Connect the negative battery cable.
17. Fill the cooling system.