Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure





1. Remove the engine cover. Refer to Fuel Injector Sight Shield Replacement (Service and Repair) .
2. Remove the air cleaner outlet duct.
3. Reposition the fresh air positive crankcase ventilation (PCV) line from the air cleaner inlet tube.




4. Disconnect the Electronic Throttle Control (ETC) electrical connector.




5. Disconnect the PCV line from the top of the intake manifold and reposition aside.




6. Disconnect the evaporative emissions (EVAP) canister purge line and reposition aside.




7. Remove the bleed pipe bolts (1).
8. Remove the bleed pipe hose clamp (2).
9. Reposition the bleed pipe.
10. Remove the brake booster vacuum hose from the intake manifold.




11. Remove the engine harness retaining clips.




12. Remove the upper intake retaining bolts.
13. Remove the upper intake manifold and gasket. Discard gasket.
14. If replacing the upper intake manifold complete the following steps:

1. Remove the evaporative emissions (EVAP) purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
2. Remove the throttle body. Refer to Throttle Body Assembly Replacement .




Installation Procedure





1. Install the upper intake manifold gaskets to the lower intake manifold and install the fir tree retainers to retain the upper intake manifold gasket position.
2. Install the upper intake manifold.

Notice: Refer to Fastener Notice .

3. Apply threadlock to the bolt threads. Refer to Sealers, Adhesives, and Lubricants (Specifications) .

Tighten the bolts to 25 N.m (18 lb ft).

4. Install the upper intake manifold bolts.
5. If the upper manifold was replaced, complete the following steps:

1. Install the throttle body. Refer to Throttle Body Assembly Replacement .
2. Install the EVAP purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .





6. Install the engine harness retaining clips.
7. Install the brake booster vacuum hose to the intake manifold.
8. Install the brake booster vacuum hose to the intake manifold.




9. Position the bleed pipe.
10. Install the bleed pipe hose clamp (2).
11. Install the bleed pipe bolts (1).

Tighten the nut to 10 N.m (89 lb in).

12. Connect the coolant hose bleed pipe.




13. Connect the EVAP canister purge line.




14. Connect the PCV line to the top of the intake manifold .




15. Connect the ETC electrical connector.
16. Install the air cleaner outlet duct.




17. Install the fresh air PCV line to the air cleaner inlet duct.
18. Install the engine cover. Refer to Fuel Injector Sight Shield Replacement (Service and Repair) .