Upper Intake Manifold Replacement

Intake Manifold Replacement (Upper)

1. Disconnect the battery negative cable.
2. Drain the engine coolant. Refer to Cooling System Draining and Filling Service and Repair.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.
4. Remove the vacuum brake booster hose, if equipped.
5. Disconnect the accelerator control and cruise control cables (if equipped). Refer to Accelerator Controls Cable Replacement Service and Repair.
6. Remove the accelerator control cable bracket and set it aside.
7. Remove the following electrical connectors:
- The SCPI injector harness connector
- The EVAP canister purge solenoid valve
- The ignition coil
- The ignition control module (ICM)
- The generator
- The idle air control (IAC) motor
- The throttle position (TP) sensor
- The oxygen (O2) sensor
- The exhaust gas recirculation (EGR) valve
- The engine coolant temperature (ECT) sensor
- The engine oil pressure sensor
- Disconnect the fuel pipes from the fuel pipes. Refer to Fuel Hose/Pipe Assembly Replacement Service and Repair.
- Remove the AIR check valve (crossover) pipe, if equipped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement Service and Repair.
- Remove the distributor cap and reposition the distributor cap out of the way. Refer to Distributor Replacement Service and Repair.






8. Remove the PCV valve hose assembly.






9. Remove the engine wiring harness bracket from the manifold.
10. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement Service and Repair.






11. Remove the studs holding the upper intake manifold to the lower intake manifold.
12. Remove the lower intake manifold. Refer to Intake Manifold Disassemble 53. Intake Manifold Disassemble.
13. Clean all the surfaces. Refer to Intake Manifold Clean and Inspect 54. Intake Manifold Clean and Inspect.

Installation Procedure

1. Install the lower intake manifold. Refer to Intake Manifold Assemble 55. Intake Manifold Assemble.
2. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement Service and Repair.






Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the engine wiring harness bracket to the upper intake manifold.

Tighten
Tighten the nut to 12 Nm (106 lb in).






4. Install the PCV valve hose assembly.
5. Install the distributor cap. Refer to Distributor Replacement Service and Repair.
6. Connect the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipe Assembly Replacement Service and Repair.
7. Install the AIR check valve (crossover) pipe, if so equipped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement Service and Repair.
8. Connect the electrical connectors.
9. Install the accelerator control cable bracket.
10. Connect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement Service and Repair.






11. Install the vacuum brake booster hose, if equipped.
12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.
13. Connect the battery negative cable.