Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure





1. Remove the fuel pipes/hoses.
2. Disconnect the cruise control cable from the throttle lever, if equipped.
3. Remove the cruise control cable from the accelerator control cable bracket, if equipped.





4. Remove the accelerator cable from the throttle body lever.





5. Remove the accelerator cable from the accelerator control cable bracket.





6. Disconnect the following electrical connectors:
^ The air conditioning (A/C) compressor clutch (1), if equipped
^ The A/C pressure switch (4), if equipped
7. Remove the engine wiring harness clip (3) from the accelerator control cable bracket.





8. Remove the accelerator control cable bracket nuts.
9. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
10. Reposition and secure the bracket and cables out of the way.





11. Disconnect the following electrical connectors:
^ The throttle position (TP) sensor (1)
^ The idle air control (IAC) motor (2)
^ The control port injector module (3)
12. Remove the engine wiring harness clip bolt (4).





13. Disconnect the following electrical connectors:
^ The evaporative emission (EVAP) canister purge solenoid valve (1)
^ The manifold absolute pressure (MAP) sensor (2)





14. Disconnect the EVAP canister tube (1) from the purge solenoid valve (2).





15. Remove the engine wiring harness bracket nuts.
16. Remove the engine wiring harness bracket.





17. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.





18. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
19. Remove the stud holding the engine wiring harness bracket.
20. Reposition the engine wiring harness with the bracket aside.





21. Remove the positive crankcase ventilation (PCV) valve hose from the valve and rocker cover.





22. Disconnect the power brake booster vacuum hose from the vacuum fitting.





23. Remove the accelerator cable bracket nuts.
24. Remove the accelerator cable bracket.





25. Remove the intake manifold-upper studs.
26. Remove the front 2 throttle body studs.
27. Remove the intake manifold-upper.





28. Remove and discard the intake manifold-upper gasket.





29. Remove and discard the O-ring seal from the fuel meter body.





30. If required, remove the power brake booster vacuum fitting.
31. Remove and discard the O-ring seal.





32. If required, remove the PCV valve cover.
33. Remove and discard the O-ring seal.





34. If required, remove the rear throttle body stud.
35. Remove the throttle body.
36. Remove and discard the throttle body gasket.





37. If required, remove the MAP sensor.
38. Remove and discard the MAP sensor seal.





39. If required, remove the EVAP canister purge solenoid valve studs.
40. Remove the purge solenoid valve.
41. Clean and inspect the intake manifold-upper, if necessary. Refer to Intake Manifold Cleaning and Inspection.

Installation Procedure





1. If required, install the purge solenoid valve.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the EVAP canister purge solenoid valve studs. If reusing the old studs, apply threadlock to the threads. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
Tighten the studs to 10 Nm (89 inch lbs.).





3. If required, install a NEW MAP sensor seal. Apply a small drop of clean engine oil to the seal.
4. Install the MAP sensor.





5. If required, install a NEW throttle body gasket.
6. Install the throttle body.
7. Install the rear throttle body stud. If reusing the old stud, apply threadlock to the threads. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
Tighten the stud to 9 Nm (80 inch lbs.).





8. If required, install a NEW O-ring seal to the PCV cover. Apply clean engine oil to the seal.
9. Install the PCV valve cover.





10. If required, install a NEW O-ring seal. Apply clean engine oil to the seal.
11. Install the power brake booster vacuum fitting.





12. Install a NEW O-ring seal to the fuel meter body.





13. Install a NEW upper intake manifold gasket.





14. Install the intake manifold - upper.
15. If reusing the old throttle body/intake manifold studs, apply threadlock to the threads. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
16. Install the front two throttle body studs.
17. Install the intake manifold - upper studs.
Tighten the studs to 9 Nm (80 inch lbs.).





18. Install the accelerator cable bracket.
19. Install the accelerator cable bracket nuts.
Tighten the nuts to 12 Nm (106 inch lbs.).





20. Connect the power brake booster vacuum hose to the vacuum fitting.





21. Install the PCV valve hose to the valve cover and rocker cover.





22. Position the engine wiring harness and bracket.
23. Install the engine wiring harness bracket stud.
Tighten the stud to 25 Nm (18 ft. lbs.).
24. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
Tighten the nut to 9 Nm (80 inch lbs.).





25. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head.
Tighten the nut to 16 Nm (12 ft. lbs.).





26. Install the engine wiring harness bracket.
27. Install the engine wiring harness bracket nuts.
Tighten the nuts to 12 Nm (106 inch lbs.).





28. Connect the EVAP canister tube (1) to the purge solenoid valve (2).





29. Connect the following electrical connectors:
^ The EVAP canister purge solenoid valve (1)
^ The MAP sensor (2)





30. Connect the following electrical connectors:
^ The TP sensor (1)
^ The IAC motor (2)
^ The control port injector module (3)
31. Install the engine wiring harness clip bolt (4).
Tighten the bolt to 9 Nm (80 inch lbs.).





32. Position the bracket and cables.
33. Install the accelerator control cable bracket with the cables attached, to the throttle body.
34. Install the accelerator control cable bracket nuts.
Tighten the nuts to 9 Nm (80 inch lbs.).





35. Connect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The A/C pressure switch (4), if equipped
36. Install the engine wiring harness clip (3) to the accelerator control cable bracket.





37. Install the accelerator cable to the accelerator control cable bracket.





38. Install the accelerator cable to the throttle body lever.





39. Install the cruise control cable to the accelerator control cable bracket, if equipped.
40. Connect the cruise control cable to the throttle lever, if equipped.
41. Install the fuel pipes/hoses.