Upper Intake Manifold

CAUTION: This engine uses a sequential multiport fuel injection system. Connect the injector connectors to their appropriate fuel injector or exhaust emissions and engine performance may be seriously affected.

REMOVAL
1. Disconnect the battery ground (negative) cable.
2. Remove the air cleaner duct. See Powertrain Management.
3. Drain the cooling system. See Cooling System.
4. Remove the accelerator control and cruise control cable with bracket from the throttle body. See Powertrain Management.
5. Disconnect the wiring harness connectors from the throttle body. See Powertrain Management.
6. Remove the thermostat bypass pipe coolant hoses from the throttle body.
7. Remove the vacuum hose connections from the throttle body.
8. Remove the front spark plug wires. See Powertrain Management.
9. Remove the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid.
10. Remove the Manifold Air Pressure (MAP) sensor and bracket. See Powertrain Management.
11. Remove the vacuum hose connections from the upper intake manifold.
12. Remove the rear generator brace.





13. Remove the Exhaust Gas Recirculation (EGR) valve. See Powertrain Management.





14. Remove the upper intake manifold studs.
15. Remove the upper intake manifold bolts.
16. Remove the upper intake manifold.





17. Remove the upper intake manifold gasket.





18. If necessary, remove the throttle body.
19. Clean the gasket with degreaser.
20. Clean the seal surfaces on the manifold with degreaser.

INSTALLATION
1. If removed, install the throttle body. See Powertrain Management.
2. Install the upper intake manifold gasket.
3. Install the upper intake manifold.
4. Install the upper intake manifold studs
5. Install the upper intake manifold bolts. Tighten the studs and bolts to 25 Nm (18 ft. lbs.).
6. Install the EGR valve. See Powertrain Management.
7. Install the rear generator brace.
8. Install the vacuum hose connections to the upper intake manifold.
9. Install the MAP sensor and bracket. See Powertrain Management.
10. Install the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid.
11. Install the front spark plug wires. See Powertrain Management.
12. Install the vacuum hose connections to the throttle body. See Powertrain Management.
13. Install the thermostat bypass pipe coolant hoses to the throttle body.
14. Connect the wiring harness connectors to the throttle body. See Powertrain Management.
15. Install the accelerator control and cruise control cable with bracket to the throttle body.
16. Refill the coolant system. See Cooling System.
17. Install the air cleaner duct. See Powertrain Management.
18. Connect the battery ground (negative) cable.