Upper Intake Manifold

Upper Intake Manifold
Removal
1. Disconnect the battery ground cable.





2. Disconnect the tubes, loosen the clamps and remove the air cleaner outlet pipe.





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





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





5. Remove the bolts and position the accelerator cables and bracket aside.





6. Disconnect the Throttle Position (TP) sensor and the Intake Air Control (IAC) electrical connectors.
^ Detach the harness retainer from the throttle body stud bolt.





7. Disconnect the vacuum hose and the Evaporative Emissions (EVAP) return tube.





8. Remove the upper intake manifold support bracket bolt and nut.
^ Position the bracket and harness aside.





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





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





11. Disconnect the fuel supply manifold pressure sensor vacuum tube.





12. Disconnect the PCV tube from the PCV valve and remove the tube.





13. Disconnect the EGR vacuum regulator solenoid and Intake Manifold Runner Control (IMRC) electrical connectors.
^ Detach the pin-type harness retainer from the upper intake manifold.





14. Detach the spark plug wire holder from the valve cover stud and disconnect the radio interference capacitor electrical connector.





15. Remove the bolts and the upper intake manifold.

Installation





1. NOTE: Clean all of the sealing surfaces. Inspect the upper intake manifold gaskets and install new gaskets as necessary.

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 inch lbs.).





2. Attach the spark plug wire holder to the valve cover stud and connect the radio interference capacitor electrical connector.





3. Connect the EGR vacuum regulator solenoid and IMRC electrical connectors.
^ Attach the pin-type harness retainer to the upper intake manifold.





4. Connect the PCV tube from the PCV valve.





5. Connect the fuel supply manifold pressure sensor vacuum tube.





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





7. Connect the EGR tube to the EGR valve and tighten the fitting.





8. Position the upper intake manifold support bracket and install bolt and nut.





9. Connect the vacuum hose and the EVAP return tube.





10. Connect the TP sensor and the IAC electrical connectors.
^ Attach the harness retainer from the throttle body stud bolt.





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





12. Connect the accelerator cable, speed control cable and throttle return spring to the throttle body.





13. Install the pin-type retainers and the snow shield.





14. Position the air cleaner outlet pipe, connect the tubes and tighten the clamps.
15. Connect the battery ground cable.