Upper Intake Manifold Replacement

AllData Editor NOTE: Other than the two torque passes listed below, the OE Manufacturer did NOT address or supply a bolt tightening sequence for the upper Intake Manifold for this model year, or other model years where this 2 piece manifold setup is used.
A "Play It Safe" final tightening sequence would be to tighten from the center most bolts to the outer most bolts.
Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Cable Replacement (Battery Disconnect/Connect) in Starting and Charging.
Remove the engine cover.
Remove the air cleaner intake duct.
2. Disconnect the following electrical connectors:
- Fuel injector electrical connector
- Manifold absolute pressure (MAP) sensor
- Canister purge solenoid
- Idle air control (IAC) solenoid
- Throttle position (TP) sensor





3. Remove the vacuum brake booster hose, if equipped.
4. Remove the PCV at the intake manifold.
Twist to unlock the PCV.





5. Disconnect the spark plug wires from the left side of the distributor cap.
6. Remove the fuel pipes from the rear of the engine.
7. Remove AIR Bypass hose assembly, if so equipped.
8. Remove the canister purge solenoid from the engine.
9. Remove the accelerator control cable and the cruise control cable, if equipped, from the throttle shaft. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
10. Remove the accelerator control cable bracket from the throttle body and set it aside.





11. Remove the upper intake manifold from the engine.
12. Clean all sealing surfaces.

Installation Procedure

AllData Editor NOTE: Other than the two torque passes listed below, the OE Manufacturer did NOT address or supply a bolt tightening sequence for the upper Intake Manifold for this model year, or other model years where this 2 piece manifold setup is used.
A "Play It Safe" final tightening sequence would be to tighten from the center most bolts to the outer most bolts.

1. Install the upper intake manifold to the engine.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the accelerator control cable bracket to the throttle body.
- Tighten the nuts to 12 Nm (106 inch lbs.).
3. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft.
4. Install the canister purge solenoid to the engine.
5. Install the fuel pipes to the rear of the engine.





6. Connect the spark plug wires to the left side of the distributor cap.
The wires and the distributor cap are numbered in order to aid assembly.
7. Install A.I.R. Bypass hose assembly, if so equipped.
8. Install the PCV to the intake manifold. Twist to lock the PCV.
9. Install the vacuum brake booster hose to the intake manifold, if equipped.
10. Connect the following electrical connectors:
- Fuel injector electrical connector
- Manifold absolute pressure (MAP) sensor
- Canister purge solenoid
- Idle air control (IAC) solenoid
- Throttle position (TP) sensor





11. Install the air cleaner intake duct.
12. Install the engine cover.
13. Connect the battery negative cable.