Upper

Upper Intake Manifold

Material:

Removal
All vehicles
1. Drain the cooling system.
2. Disconnect the battery ground cable.
3. Remove the air cleaner outlet pipe.
4. Remove the 4 transaxle roll restrictor cross brace bolts.
5. Remove the bolt and the transaxle roll restrictor cross brace.
6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer.
7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold.
8. Detach the fuel tube retainer from the upper intake manifold.
9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube.
10. Detach the vacuum tube from the upper intake manifold vacuum tube retainer.
11. Disconnect the EGR system module tube from the EGR system module.

Early build
12. Disconnect and plug the throttle body and PCV coolant hoses.

Late build
13. Disconnect and plug the 2 PCV coolant hoses.

All vehicles
14. Disconnect the throttle body electrical connector.
15. If equipped, remove and discard the 4 upper-to-lower intake manifold screws.
16. Remove the 8 bolts and the upper intake manifold.
^ Remove and discard the gaskets.

Installation





All vehicles

1. NOTE: Clean and inspect all sealing surfaces. Install new gaskets.

Position the upper intake manifold and install the 8 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

2. Connect the throttle body electrical connector.

Late build
3. Connect the 2 PCV coolant hoses.

Early build
4. Connect the throttle body and PCV coolant hoses.

All vehicles
5. Connect the EGR system module tube to the EGR system module.
^ Tighten to 40 Nm (30 ft. lbs.).

6. Attach the vacuum tube to the upper intake manifold vacuum tube retainer.
7. Connect the EGR system module electrical connector and vacuum tube.
8. Attach the fuel tube retainer to the upper intake manifold.
9. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold.
10. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer.
11. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads.
12. Position the transaxle roll restrictor cross brace and install the 4 new bolts.
^ Tighten to 55 Nm (41 ft. lbs.).

13. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads.
14. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt.
^ Tighten to 48 Nm (35 ft. lbs.).

15. Install the air cleaner outlet pipe.
16. Connect the battery ground cable.
17. Fill and bleed the cooling system.