Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure





1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair) .
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
3. Remove the intake manifold insulator. Refer to Intake Manifold Insulator Replacement (Service and Repair) .
4. Disconnect the evaporative emissions (EVAP) canister purge line (1) and reposition aside.
5. Disconnect the PCV line (2) from the top of the intake manifold and reposition aside.
6. Disconnect the intake manifold tuning valve electrical connector (3).
7. Remove the brake booster vacuum hose (4) from the intake manifold.
8. Disconnect the electronic throttle control (ETC) electrical connector (5).




9. Remove the engine harness bracket retaining bolt (1).
10. Disconnect the map sensor electrical connector (2).




11. Remove the upper intake retaining bolts.
12. Remove the upper intake manifold and gasket. Discard gasket.
13. If replacing the upper intake manifold complete the following steps:

1. Remove the evaporative emissions (EVAP) purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
2. Remove the intake manifold tuning valve. Refer to Intake Manifold Tuning Valve Replacement .
3. Remove the throttle body. Refer to Throttle Body Assembly Replacement .




Installation Procedure





1. Install the upper intake manifold gaskets to the lower intake manifold and install the fir tree retainers to retain the upper intake manifold gasket position.
2. Install the upper intake manifold.

Notice: Refer to Fastener Notice .

3. Apply threadlock to the bolt threads. Refer to Sealers, Adhesives, and Lubricants (Specifications) . Install the upper intake manifold bolts.

Tighten the bolts to 23 N.m (17 lb ft).

4. If the upper manifold was replaced, complete the following steps:

1. Install the throttle body. Refer to Throttle Body Assembly Replacement .
2. Install the intake manifold tuning valve. Refer to Intake Manifold Tuning Valve Replacement .
3. Install the EVAP purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .





5. Connect the map sensor electrical connector (2).
6. Install the engine harness bracket retaining bolt (1).




7. Connect the ETC electrical connector (5).
8. Install the brake booster vacuum hose (4) to the intake manifold.
9. Connect the intake manifold tuning valve electrical connector (3).
10. Connect the PCV line (2) to the top of the intake manifold.
11. Connect the EVAP canister purge line (1).
12. Install the intake manifold insulator. Refer to Intake Manifold Insulator Replacement (Service and Repair) .
13. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
14. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair) .