Upper Intake Manifold Replacement

Removal Procedure
1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement (Battery Cable Negative) in Starting and Charging.
2. Remove the air intake duct from the throttle body.
3. Remove the air cleaner assembly from vehicle.





4. Remove the crankcase vent tube from the throttle body.





5. Remove the PCV valve from the valve rocker arm cover.





6. Remove the EGR pipe from the upper intake manifold.
7. Remove the ignition coil from the intake manifold.
8. Remove the throttle body from the upper intake manifold.
9. Remove the EVAP canister solenoid valve.
10. Remove the number 8 spark plug wire from the distributor.





11. Remove the upper intake manifold bolts.
12. Remove the upper intake manifold and gaskets from the lower intake manifold.
13. Clean the excessive carbon deposit from the exhaust and the EGR valve passages.

Installation Procedure





1. Install the upper intake manifold and gaskets to the lower intake manifold.

Important: Failure to follow the procedure listed, could cause a drive ability problem.

2. Coat a minimum of eight threads of the bolts with thread locking sealant G/M P/N 12345493.

Notice: Refer to Fastener Notice in Service Precautions.





3. Install the upper intake manifold bolts and tighten in the following manner.
3.1. Tighten the bolts in sequence to 8 Nm (71 inch lbs.).
3.2. Re tighten the bolts in sequence to 18 Nm (13 ft. lbs.).
4. Install the number 8 spark plug wire.
5. Install the ignition coil to the upper intake manifold.
6. Install the EGR valve if necessary.





7. Install the EGR pipe to the upper intake manifold.
^ Tighten EGR valve fittings to 60 Nm (46 ft. lbs.).
8. Install the EVAP canister solenoid valve to the intake manifold.
9. Install the throttle body to the upper intake manifold.





10. Install the PCV valve to the valve rocker arm cover to the cylinder head.





11. Install the crankcase vent tube to the valve rocker arm cover.
12. Install the air intake duct to the throttle body.
13. Connect the battery negative cables to the battery.
14. Install Engine Cover.