Upper Intake Manifold Replacement

Removal Procedure





1. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement.
2. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement.
3. Remove the air intake duct from the turbocharger.





4. Remove the CDR valve from the air intake duct.





5. Remove the electrical harness and retaining brackets from the upper intake manifold (if needed).





6. Remove the transmission oil level indicator tube from the upper intake manifold.
7. Remove the rear air conditioning line from the upper intake manifold (if equipped).





Important: Do not attempt to remove the upper intake manifold with the lower intake manifold as an assembly. The upper and lower intake manifolds will not align with the turbocharger or the bolt holes for either of the intake manifold bolts for reassembly.

8. Remove the upper intake manifold bolts.
9. Remove the upper intake manifold and gaskets from the lower intake manifold.


Installation Procedure

Important: Always replace the O-ring between the upper intake manifold and the turbocharger. Coat the new O-ring with clean engine oil before installing on the turbocharger.

Notice: Refer to Fastener Notice in Service Precautions.





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





2. Install the electrical harness and retaining brackets to the upper intake manifold.
3. Install the rear A/C line to the upper intake manifold (if equipped).





4. Install the transmission oil level indicator tube to the upper intake manifold.





5. Install the air intake duct to the turbocharger.
6. Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement.





7. Install the CDR valve to the air intake duct.
8. Install the engine cover in the vehicle. Refer to Engine Cover Replacement.