Upper Intake Manifold Replacement

Intake Manifold Replacement (Upper)

Removal Procedure

1. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.






3. Disconnect the following electrical connectors:
- The A/C pressure switch, if equipped.
- The throttle position (TP) sensor.
- The idle air control (IAC) motor.
- The fuel meter body assembly connector.
- The manifold absolute pressure (MAP) sensor.
- The EVAP canister purge solenoid valve.
4. Remove the EVAP canister purge solenoid valve.






5. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.
6. Remove the vacuum brake booster hose.






7. Remove the PCV valve hose assembly form the intake manifold and the valve rocker arm cover.






8. Disconnect the accelerator control cable from the throttle shaft and the accelerator cable bracket. Refer to Accelerator Control Cable Replacement.
9. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement.
10. Remove the accelerator cable bracket from the throttle body and the intake manifold.






11. Remove the accelerator and cruise control cable bracket from the throttle body.
- Leave the accelerator and cruise control cables and the engine wiring harness on the bracket.






12. Remove the bracket for the engine wiring harness from the intake stud.
13. Remove the fuel lines from the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement - Engine Compartment.






14. Remove the upper intake manifold.
15. Clean all sealing surfaces.

Installation Procedure






1. Install the upper intake manifold.
2. Install the fuel lines to the fuel meter body assembly. Refer to Fuel Hose/Pipes Replacement - Engine Compartment.






3. Install the bracket for the engine wiring harness on the lower intake manifold stud.

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.

4. Install the engine wiring harness bracket nut. Tighten the engine wiring harness bracket nut to 12 Nm (106 lb in).






5. Install the accelerator and cruise control cable bracket to the throttle body.
6. Install the accelerator and cruise control cable bracket nuts. Tighten the accelerator and cruise control cable bracket nuts to 9 Nm (80 lb in).






7. Install the accelerator control cable bracket to the throttle body and the intake manifold. Tighten the accelerator control cable bracket studs and nuts to 12 Nm (106 lb in).
8. Install the cruise control cable, if equipped to the throttle shaft and the bracket.
9. Install the accelerator control cable to the throttle shaft and the bracket.
10. Install the EVAP canister purge solenoid valve.






11. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.






12. Connect the vacuum hose to the intake manifold, if equipped with A/C.
13. Install the vacuum brake booster hose to the intake manifold.






14. Connect the following electrical connectors:
- The A/C pressure switch, if equipped.
- The throttle position (TP) sensor.
- The idle air control (IAC) motor.
- The fuel meter body assembly connector.
- The manifold absolute pressure (MAP) sensor.
- The EVAP canister purge solenoid valve.
15. Install the air cleaner assembly.
16. Install the air cleaner outlet duct to the throttle body assembly.