Upper Intake Manifold

INTAKE MANIFOLD UPPER

REMOVAL





1. Disconnect negative battery (1) cable.





2. Remove throttle body air inlet hose and air cleaner housing assembly (3).
3. Disconnect electrical connectors from the following components:
^ Manifold Absolute Pressure (MAP) Sensor
^ Electronic Throttle Control
^ Manifold Tuning Valve
4. Disconnect Vapor Purge hose, Brake Booster hose, Positive Crankcase Ventilation (PCV) hose.





5. Remove manifold support brackets (1).





6. Remove manifold attaching bolts.





7. Remove upper manifold (2).
8. Remove foam insulator (3).
9. Inspect manifold (2).

INSPECTION
Check manifold for:
^ Damage and cracks
^ Gasket surface damage or warpage
^ Damaged or clogged EGR ports

If the manifold exhibits any damaged or warped conditions, replace the manifold. Clean EGR ports as necessary.
If a vacuum port is damaged, a repair procedure can be performed.

INSTALLATION
1. Clean and inspect sealing surfaces. Gaskets can be reused, if free of cuts or tears.

NOTE: Make sure fuel injectors and wiring harnesses are in correct position to not interfere with upper manifold installation.

2. Install upper manifold gasket.
3. Position upper manifold onto lower manifold.





4. Install manifold attaching bolts and tighten in sequence shown in to 12 Nm (105 inch lbs.).
5. Connect PCV, brake booster, and vapor purge hoses.
6. Connect electrical connectors to the following components:
^ Manifold Absolute Pressure (MAP) Sensor
^ Electronic Throttle Control
^ Manifold Tuning Valve

7. Install throttle body air inlet hose and air cleaner housing assembly.





8. Connect negative battery (1) cable.