Upper Intake Manifold Replacement

Intake Manifold Replacement - Upper

Removal Procedure





1. Disconnect the battery negative cable.
2. Remove the engine cover. Refer to: Service and Repair
3. Remove the air cleaner intake duct. Refer to: Service and Repair
4. Disconnect the following electrical connectors:
- Fuel injector electrical connector.
- Manifold Absolute Pressure (MAP) sensor.
- EVAP canister purge solenoid valve.
- Idle Air Control (IAC) solenoid.
- Throttle Position (TP) sensor.
5. Remove the vacuum brake booster hose, if equipped.
6. Remove the PCV tube at the intake manifold. Twist to unlock the PCV tube.





7. Disconnect the spark plug wires from the left side of the distributor cap.
8. Remove the fuel pipes from the rear of the engine.
9. Remove AIR Bypass hose assembly, if so equipped.
10. Remove the EVAP canister purge solenoid valve from the engine. Refer to: Service and Repair
11. Remove the accelerator control cable and the cruise control cable, if equipped, from the throttle shaft. Refer to: Service and Repair
12. Remove the accelerator control cable bracket from the throttle body and the intake manifold and set it aside.





13. Remove the upper intake manifold bolts from the engine and then remove the upper intake manifold. Refer to: Overhaul
14. Clean all sealing surfaces.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.





1. Install the upper intake manifold to the engine. Refer to: Overhaul
1.1. Tighten the upper intake manifold studs on the first pass to 12 Nm (44 inch lbs.).
1.2. Tighten the upper intake manifold studs on the second pass to 10 Nm (89 inch lbs.).
2. Install the accelerator control cable bracket (3) to the throttle body and the lower intake manifold.
- Tighten the bolts and nut to 12 Nm (106 inch lbs.).
3. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft. Refer to: Service and Repair
4. Install the EVAP canister purge solenoid valve to the engine. Refer to: Service and Repair
5. Install the fuel pipes to the rear of the engine.





6. Connect the spark plug wires to the left side of the distributor cap. The wires and the distributor cap are numbered in order to aid assembly.
7. Install AIR bypass hose assembly, if so equipped.
8. Install the PCV tube to the intake manifold. Twist to lock the PCV tube.
9. Install the vacuum brake booster hose to the intake manifold, if equipped.
10. Connect the following electrical connectors:
- Fuel injector electrical connector.
- Manifold Absolute Pressure (MAP) sensor.
- EVAP canister purge solenoid valve.
- Idle Air Control (IAC) solenoid.
- Throttle Position (TP) sensor.
11. Install the air cleaner intake duct. Refer to: Service and Repair
12. Install the engine cover. Refer to: Service and Repair
13. Connect the battery negative cable.