Upper Intake Manifold

Upper Intake Manifold

Removal
1. Disconnect the battery ground cable.
2. Remove the air cleaner assembly and the air cleaner outlet tube.





3. Remove the pin-type retainers and the snow shield.





4. Disconnect the accelerator cable, speed control actuator cable and the throttle return spring from the throttle body.





5. Remove the bolts, then position the accelerator cable bracket aside.





6. Disconnect the hoses.
- Disconnect the vacuum hose.
- Disconnect the Evaporative Emissions (EVAP) return tube.





7. Disconnect the Idle Air Control (IAC) valve and the Throttle Position (TP) sensor electrical connectors.





8. Disconnect the engine wiring harness from the intake manifold support bracket.





9. Remove the upper intake manifold support bracket.





10. Disconnect the Positive Crankcase Ventilation (PCV) tube from the upper intake manifold.





11. Loosen the nut and disconnect the Exhaust Gas Recirculation (EGR) tube from the EGR valve.





12. Disconnect the vacuum hose from the EGR valve.





13. Disconnect the vacuum regulator solenoid vacuum and electrical connections. Disconnect the vacuum hose from the upper intake manifold.





14. Disconnect the wire harness retaining clip.





15. Disconnect the spark plug holder and the radio interference capacitor electrical connector.





16. Remove the bolts and the upper intake manifold.

Installation
1. Clean all the sealing surfaces.





2. Inspect the upper intake manifold gaskets. Install new gasket as necessary.

Upper Intake Manifold:

3. Install the upper intake manifold. Tighten bolts in two stages in the sequence shown.
1 Stage 1: Tighten the bolts hand tight.
2 Stage 2: Tighten the bolts to 10 Nm (89 in. lbs.).





4. Connect the spark plug holder and the radio interference capacitor electrical connector.





5. Connect the wire harness retaining clip.





6. Connect the vacuum regulator solenoid vacuum and electrical connections. Connect the vacuum hose to the upper intake manifold.





7. Connect the vacuum hose to the EGR valve.





8. Connect the EGR tube to the EGR valve.





9. Connect the PCV tube to the upper intake manifold.





10. Install the upper intake manifold support bracket.





11. Connect the engine wiring harness to the intake manifold support bracket.





12. Connect the IAC and TP sensor electrical connectors.





13. Connect the evaporative emissions return tube and the vacuum hose.





14. Position the accelerator cable bracket and install the bolts.





15. Connect the accelerator control cable, speed control cable and the throttle return spring.





16. Install the snow shield.
17. Install the air cleaner assembly and the air cleaner outlet tube.
18. Connect the battery ground cable.