Upper Intake Manifold

Removal
1. Disconnect battery ground cable.
2. Remove engine appearance cover.
3. Remove right half of cowl vent screen.
4. Remove throttle body.
5. Disconnect the main emission vacuum supply hose from the surge tank vacuum fitting and EGR valve (EGR valve). Position vacuum supply hose out of the way.
6. Disconnect vacuum tube from intake manifold vacuum union.





7. Remove the two retaining bolts for the transducer mounting bracket from the surge tank. Position the transducer mounting bracket out of the way.
8. Remove the two intake manifold supports from the surge tank and cylinder head.
9. Remove EGR valve.
10. Remove retaining bolts and surge tank stay from front of surge tank.
11. Remove bolt, nuts and surge tank stay from rear of surge tank.
12. Disconnect crankcase ventilation tube from valve cover.





13. Disconnect crankcase ventilation tube from surge tank.
14. Disconnect vacuum tube to fuel pressure regulator.
15. Disconnect RH crankcase ventilation hose and position aside.
16. Loosen intake air connector hose clamps and remove surge tank from engine.
17. Remove radio ignition interference capacitor bracket retaining bolt and position radio ignition interference capacitor aside.

18. CAUTION: When removing engine components, always remove retaining bolts in reverse of tightening sequence (as shown) or damage to engine components may occur.

Remove intake manifold retaining bolts in standard loosening sequence.
19. Remove upper intake manifold and intake manifold upper gaskets from lower intake manifold and discard intake manifold upper gaskets.

Installation

1. CAUTION: New upper intake manifold gaskets must be used or damage to the engine may occur.

Position new upper intake manifold gaskets on lower intake manifold.

2. CAUTION: Upper intake manifold bolts must be tightened in sequence shown or damage to the engine may occur.





Position upper intake manifold on lower intake manifold and install retaining bolts. Tighten bolts in standard tightening sequence to 18-28 Nm (14-20 ft. lbs.)
3. Install radio ignition interference capacitor bracket and retaining bolt. Tighten retaining bolt to 8-12 Nm (71-106 inch lbs.)





4. Position surge tank on engine and align intake air connector clamps as shown. Tighten clamps securely.
5. Connect RH crankcase ventilation hose.
6. Connect vacuum tube from fuel pressure regulator to surge tank fitting.
7. Connect crankcase ventilation tube to surge tank fitting.
8. Connect crankcase ventilation tube to valve cover.
9. Install rear surge tank stay and retaining bolts and two nuts. Tighten bolt and nuts to 18-28 Nm (14-20 ft. lbs.)
10. Install front surge tank stay and retaining bolts. Tighten retaining bolts to 18-28 Nm (14-20 ft. lbs.)
11. Install EGR valve.
12. Install two intake manifold supports from surge tank to cylinder head. Tighten retaining bolts to 18-28 Nm (14-20 ft. lbs.)








13. Position transducer mounting bracket on surge tank and install retaining bolts. Tighten bolts to 18-28 Nm (14-20 ft. lbs.)
14. Connect vacuum tube to intake manifold vacuum union.
15. Connect main emission vacuum supply hose to the surge tank fitting and EGR valve.
16. Install throttle body.
17. Install right half of cowl vent screen.
18. Install engine appearance cover.
19. Connect battery ground cable.