Intake Manifold Replacement (Upper)

REMOVAL PROCEDURE





1. Remove the engine cover.
2. Remove the air cleaner assembly.
3. Disconnect the PCV tube from the air inlet duct.
4. Remove the air cleaner outlet duct from the throttle body.
5. Disconnect the following electrical connectors:
^ The Throttle Position (TP) sensor
^ The Idle Air Control (IAC) motor
^ The fuel meter body assembly connector The Manifold Absolute Pressure (MAP) sensor The EVAP canister purge solenoid valve





6. Remove the PCV valve hose from the intake manifold and the valve rocker arm cover.





7. Disconnect the A/C vacuum hose from the intake manifold, if equipped with A/C.
8. Remove the vacuum brake booster hose bracket from the upper intake stud.
9. Disconnect the vacuum brake booster hose from the intake manifold.
10. Remove the EVAP canister purge solenoid valve.





11. Disconnect the accelerator control cable from the throttle shaft.
12. Disconnect the cruise control cable.
13. Remove the studs and nuts for the accelerator control cable bracket.
14. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
15. Remove the distributor cap.
16. Remove the ignition coil module.
17. Remove the fuel lines from the fuel meter body assembly.
18. Remove the throttle body assembly.





19. Remove the upper intake manifold. Refer to Intake Manifold Disassemble under Engine Unit Repair.
20. Clean all sealing surfaces. Refer to Intake Manifold Clean and Inspect under Engine Unit Repair.

INSTALLATION PROCEDURE





1. Install the upper intake manifold. Refer to Intake Manifold Assemble under Engine Unit Repair.
2. Install the throttle body assembly.
3. Install the fuel lines to the fuel meter body assembly.
4. Install the distributor cap.
5. Install the ignition coil module.





6. Install the accelerator control and cruise control cable bracket, studs, and nuts to the throttle body and the intake manifold.
^ Tighten the cable bracket nuts and bolts to 12 Nm (106 inch lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

7. Install the cruise control cable, if equipped.
8. Install the accelerator control cable to the throttle shaft.
9. Install the EVAP canister purge solenoid valve.





10. Connect the vacuum brake booster hose to the intake manifold.
11. Install the vacuum brake booster hose bracket and nut on the intake manifold stud.
^ Tighten the nut to 11 Nm (97 inch lbs.).

12. Connect the A/C vacuum hose to the intake manifold, if equipped with A/C.





13. Connect the PCV valve hose to the intake manifold and the valve rocker arm cover.
14. Connect the following electrical connectors:
^ The Throttle Position (TP) sensor
^ The Idle Air Control (IAC) motor
^ The fuel meter body assembly connector
^ The Manifold Absolute Pressure (MAP) sensor
^ The EVAP canister purge solenoid valve





15. Install the air cleaner outlet duct to the throttle body assembly.
16. Connect the PCV tube to the air inlet duct.
17. Install the air cleaner assembly.
18. Install the engine cover.