Upper

UPPER






NOTE: Prior to installing the upper intake manifold, verify that the four fuel rail bolts were not inadvertently loosened. The bolts must tightened in the sequence shown to 7 Nm (62 in. lbs.) Fuel Rail - Installation .






1. Clean and inspect the sealing surfaces. Install new upper to lower intake manifold seals (1).

NOTE: Make sure the fuel injectors and wiring harnesses are in the correct position so that they don't interfere with the upper intake manifold installation.

2. If removed, install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.





3. Lift and hold the seven upper intake attaching bolts (1) clear of the mating surface. Back the bolts out slightly or if required, use an elastic band to hold the bolts clear of the mating surface.
4. Position the upper intake manifold (1) onto the lower intake manifold so that the two locating posts (2) on the upper intake manifold align with corresponding holes (3) in the lower intake manifold.





5. Install the seven upper intake manifold attaching bolts. Tighten the bolts in the sequence shown to 8 Nm (71 in. lbs.).





6. Install two nuts (1) to the upper intake manifold support bracket (5). Tighten the nuts (1) to 10 Nm (89 in. lbs.) and tighten the studbolt (2) to 20 Nm (177 in. lbs.)
7. Engage the wire harness retainer (3) to the studbolt (2).
8. Engage the wire harness retainer (4) to the upper intake manifold support bracket (5).





9. Install two upper intake manifold support brackets (2) with two studbolts (3) and two nuts (1). Tighten the studbolts (3) to 20 Nm (177 in. lbs.) and tighten the nuts (1) to 10 Nm (89 in. lbs.).





10. Install the nut (2) to the support bracket of the heater core return tube (1) and tighten to 12 Nm (106 in. lbs.).





11. Connect the following hoses to the upper intake manifold:
- Positive Crankcase Ventilation (PCV) (3)
- vapor purge (6)
- brake booster (2)

12. Connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (7).
13. Secure the ETC harness to the clip (7) on the throttle body and engage the wire harness retainers (4 and 5) to the upper intake manifold near the MAP sensor.





14. Install the resonator (1) Installation.





15. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
16. Start and run the engine until it reaches normal operating temperature.
17. Install the engine cover (1).