Intake Manifold Replacement (Upper)
REMOVAL PROCEDURE
1. Disconnect the PCV tube from the air cleaner outlet duct.
2. Remove the air cleaner outlet duct from the throttle body.
3. Remove the air cleaner assembly.
4. Disconnect the following electrical connectors:
^ The A/C pressure switch, if equipped.
^ 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.
5. Remove the EVAP canister purge solenoid valve.
6. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.
7. Remove the vacuum brake booster hose.
8. Remove the PCV valve hose assembly form the intake manifold and the valve rocker arm cover.
9. Disconnect the accelerator control cable from the throttle shaft and the accelerator cable bracket.
10. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket.
11. Remove the accelerator cable bracket from the throttle body and the intake manifold.
12. Remove the accelerator and cruise control cable bracket from the throttle body.
Leave the accelerator and cruise control cables and the engine wiring harness on the bracket.
13. Remove the bracket for the engine wiring harness from the intake stud.
14. Remove the fuel lines from the fuel meter body assembly.
15. Remove the upper intake manifold.
16. Clean all sealing surfaces.
INSTALLATION PROCEDURE
INSTALLATION
1. Install a new upper intake manifold gasket.
a. 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.
b. Install the remaining intake manifold bolts and studs.
c. Tighten the upper intake manifold bolts in two steps.
d. Tighten the bolts to 5 Nm (44 inch lbs.).
e. Final tighten the bolts to 9 Nm (80 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.
2. Install the fuel lines to the fuel meter body assembly.
3. Install the bracket for the engine wiring harness on the lower intake manifold stud.
NOTICE: Refer to Fastener Notice in Service Precautions.
4. Install the engine wiring harness bracket nut.
^ Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.).
5. Install the accelerator and cruise control cable bracket to the throttle body.
6. Install the accelerator and cruise control cable bracket nuts.
^ Tighten the accelerator and cruise control cable bracket nuts to 9 Nm (80 inch lbs.).
7. Install the accelerator cable bracket to the throttle body and the intake manifold.
^ Tighten the accelerator cable bracket studs and nuts to 12 Nm (106 inch lbs.).
8. Install the cruise control cable, if equipped to the throttle shaft and the bracket.
9. Install the accelerator cable to the throttle shaft and the bracket.
10. Install the EVAP canister purge solenoid valve.
11. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
12. Connect the vacuum hose to the intake manifold, if equipped with A/C.
13. Install the vacuum brake booster hose to the intake manifold.
14. Connect the following electrical connectors:
^ The A/C pressure switch, if equipped
^ 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 assembly.
16. Install the air cleaner outlet duct to the throttle body assembly.
17. Connect the PCV tube to the air cleaner outlet duct.