Intake Manifold Replacement (Upper)

REMOVAL
1. Drain the engine coolant. Refer to Cooling System.
2. Remove the air cleaner and air inlet duct.
3. Remove the following wire harnesses:
^ The Throttle Position Sensor (TP sensor)
^ The Idle Air Control (IAC) motor.
^ The Manifold Absolute Pressure (MAP) sensor
4. Remove the throttle linkage. Refer to Powertrain Management.
5. Remove the ignition coil. Refer to Starting and Charging.
6. Remove the Positive Crankcase Ventilator (PCV) pipe.
7. Remove the vacuum hoses.





8. Remove the upper intake manifold bolts.
9. Remove the upper intake manifold.

Upper Intake Manifold Installation:

10. Remove the gaskets.

INSTALLATION
1. Install a new upper intake manifold gasket.
2. Install the upper intake manifold. Do not pinch the injector wires between the upper and lower intake manifolds.

NOTE: Install two stud bolts through the upper intake manifold diagonally opposite from each other to aid in positioning upper intake manifold to the lower intake manifold.





3. Install the remaining intake manifold bolts and studs.
4. Tighten the upper intake manifold bolts in two steps.
a. Tighten the bolts to 5 Nm (44 inch lbs.).
b. Final tighten the bolts to 10 Nm (89 inch lbs.).

AllData Editor NOTE: Other than the two torque passes listed above, the OE Manufacturer did NOT address or supply a bolt tightening sequence for the upper Intake Manifold for this model year, or other model years where this 2 piece manifold setup is used.
A "Play It Safe" final tightening sequence would be to tighten from the center most bolts to the outer most bolts.







5. Install the PCV pipe.





6. Install the vacuum hoses.
7. Install the throttle linkage.





8. Install the ignition coil.
9. Install the following wiring harnesses:
^ The TP sensor
^ The IAC motor
^ The MAP sensor
10. Install the air cleaner and the air inlet duct.
11. Fill the cooling system.