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, position the insulator (2) onto the two alignment posts (3) on top of the left 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 (2). Tighten the nuts (1) to 10 Nm (89 in. lbs.) and tighten the stud (3) to 20 Nm (15 ft. lbs.)
7. Engage the wire harness retainer (4) to the stud (3).





8. Install the two upper intake manifold support brackets (2) with two stud retainers (3) and two nuts (1). Tighten the stud retainers (3) to 20 Nm (15 ft. lbs.) and tighten the nuts (1) to 10 Nm (89 in. lbs.).





9. Position the heater core return tube (1), install the retaining nut (2) and tighten to 12 Nm (9 ft. lbs.).





10. Connect the following hoses to the upper intake manifold:
- Positive Crankcase Ventilation (PCV) (7)
- Brake booster vacuum hose (6)
- EVAP vapor purge line (3)

11. Connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (2) and the Electronic Throttle Control (ETC) (4).
12. Secure the ETC harness to the clip (5) on the throttle body and fasten the wire harness retainer (1) to the upper intake manifold near the MAP sensor.





13. Fasten the brake booster vacuum hose retainer (1) to the upper intake manifold.





14. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
15. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
16. Tighten the clamp at the air cleaner housing (3) to 5 Nm (44 in. lbs.).
17. Tighten the clamp (2) at the throttle body to 5 Nm (44 in. lbs.).
18. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).





19. Position the engine cover (1) and secure the retaining grommets onto the ball studs.





20. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
21. Start the engine and check for leaks.