Upper Intake Manifold Replacement

Removal Procedure





1. Remove the upper intake manifold cover from the upper intake manifold.
2. Disconnect both the battery negative cables from the batteries. Refer to Battery Replacement.





3. Remove the braces from the turbocharger to the upper intake manifold.





4. Remove the boost pressure sensor from the upper intake manifold.





5. Remove the intake air temperature sensor from the upper intake manifold.





Important: In order to loosen the sealer, run a small screw driver (flat blade) between the hose and the upper intake manifold. Use caution as not to damage the hose.

6. Loosen the clamps on the hose between the turbocharger and the upper intake manifold.





Important: When removing the upper intake manifold, rotate the upper intake manifold in a downward then in a upward motion to help loosen the silicone sealant on the air intake hose.

7. Remove the upper intake manifold from the lower intake manifold.





8. Remove the upper intake manifold gasket from the lower intake manifold gasket.


Installation Procedure

Important: Install the air intake hose between the upper intake manifold and the turbocharger on the upper intake manifold first before installing the upper intake manifold.





1. Apply a small amount of silicone sealer to the hose between the turbocharger inlet and the upper intake manifold.





2. Install the new upper intake manifold gasket.





3. Install the upper intake manifold.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the mounting bolts in the upper intake manifold.
^ Tighten the bolts to 23 Nm (17 ft. lbs.).





5. Tighten the air intake hose clamps on the upper intake manifold.
^ Tighten the clamps to 6 Nm (50 inch lbs.).
6. Install the boost pressure sensor on the upper intake manifold. Refer to Boost Sensor Replacement.
7. Install the intake air temperature sensor to the upper intake manifold. Refer to AT Sensor Replacement.
8. Install the braces from the turbocharger to the upper intake manifold. Refer to Turbocharger Replacement.





9. Install the upper engine cover to the upper intake manifold.
10. Connect both the battery negative cables to the batteries. Refer to Battery Replacement.