Upper Intake Manifold Replacement

Removal Procedure





1. Remove the engine cover.
2. Remove the air cleaner outlet duct from the throttle body.
3. 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





4. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
5. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.





6. Remove the engine wiring harness bracket from the stud at the EVAP canister purge solenoid valve.
7. Remove the EVAP canister purge solenoid. Refer to EVAP Canister Purge Solenoid Valve Replacement in Powertrain Management.





8. Disconnect the accelerator control cable from the throttle shaft. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
9. Disconnect the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
10. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket.
11. Remove the accelerator control cable bracket from the throttle body and the intake manifold.





12. Remove the nut holding the A/C hose bracket, if equipped to the intake manifold stud.
13. Remove the A/C hose bracket from the stud.
14. Remove the nut holding the engine wiring harness bracket to the intake manifold stud.
15. Remove the engine wiring harness bracket from the stud.
16. Remove the fuel lines from the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.





17. Remove the upper intake manifold.
18. Clean all sealing surfaces.


Installation Procedure





1. Install the upper intake manifold.
2. Install the fuel lines to the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.





Notice: Refer to Fastener Notice in Service Precautions.

3. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body
Tighten the accelerator control cable bracket nuts and studs to 12 Nm (106 inch lbs.).
4. Install the transmission fluid fill tube and bolt to the accelerator control cable bracket.
Tighten the transmission fluid fill tube bolt 6 Nm (53 inch lbs.).
5. Install the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
6. Install the accelerator control cable to the throttle shaft. Refer to Accelerator Controls Cable Replacement in Powertrain Management.





7. Install the engine wiring harness bracket and nut to the intake manifold stud.
Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.).
8. Install the A/C hose bracket and nut, if equipped to the intake manifold stud.
Tighten the A/C hose bracket nut to 5 Nm (44inch lbs.).





9. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Powertrain Management.
10. Install the engine wiring harness bracket and the nut onto the stud at the EVAP canister purge solenoid valve.
Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.).





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. 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
14. Install the air cleaner outlet duct to the throttle body assembly.
15. Install the engine cover.