Upper Intake Manifold Replacement

Removal Procedure

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





1. Disconnect the battery ground (negative) cable. Refer to Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Disconnect the vacuum hose connection from the throttle body air inlet duct.
3. Disconnect the wiring harness connection from the Intake Air Temperature (IAT) sensor in the throttle body air inlet duct. Refer to IAT Sensor Replacement in Powertrain Management.
4. Remove the throttle body air inlet duct.
5. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
6. Remove the accelerator control and cruise control cables with bracket from the throttle body. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
7. Disconnect the wiring harness connectors from the throttle body.
^ Throttle Position (TP) sensor
^ Idle air control (IAC) valve

8. Disconnect the (left) front spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
9. Disconnect the wiring harness attachment clips.
^ Camshaft Position (CMP) sensor wiring harness
^ Left spark plug wire harness
^ Engine wiring harness

10. Disconnect the thermostat bypass pipe coolant hoses from the throttle body.
11. Remove the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid. Refer to Ignition Coil(s) Replacement and EVAP Canister Purge Valve Replacement in Powertrain Management.
12. Disconnect the vacuum hose at the Manifold Air Pressure (MAP) sensor and upper intake manifold.
13. Remove the manifold air pressure (MAP) sensor and the bracket. Refer to MAP Sensor Replacement in Powertrain Management.





14. Disconnect the emission control vacuum harness.
15. Disconnect the vacuum hose connections from the upper intake manifold.
^ Vacuum booster hose
^ Automatic transaxle vacuum modulator hose
^ Heater and air conditioning vacuum source hose
^ Fuel pressure regulator

16. Remove the generator brace. Refer to Generator Brace Replacement in Starting and Charging.
17. Remove the generator bracket. Refer to Battery Replacement





18. Remove the Exhaust Gas Recirculation (EGR) valve. Refer to EGR Valve Replacement in Powertrain Management.





19. Remove the right upper intake manifold bolts and studs.





20. Remove the left upper intake manifold bolts,
21. Remove the upper intake manifold.





22. Remove the upper intake manifold gasket.





23. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Powertrain Management.
24. Clean the seal surfaces on the manifold with degreaser.

Installation Procedure





1. Install the throttle body. Refer to Throttle Body Assembly Replacement in Powertrain Management.





2. Install the upper intake manifold gasket.





3. Install the upper intake manifold.
4. Loosely install the left upper intake manifold bolts.





5. Loosely install the right upper intake manifold bolts and studs.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the upper intake manifold bolts and studs.
Tighten the upper intake manifold bolts and studs to 25 Nm (18 ft. lbs.).





7. Install the exhaust gas recirculation (EGR) valve. Refer to EGR Valve Replacement in Powertrain Management.
8. Install the generator bracket. Refer to Battery Replacement
9. Install the generator brace. Refer to Generator Brace Replacement in Starting and Charging.
10. Connect the vacuum hose connections to the upper intake manifold.
^ Vacuum booster hose
^ Automatic transaxle vacuum modulator hose
^ Heater and air conditioning vacuum source hose
^ Fuel pressure regulator





11. Connect the emission control vacuum harness.
12. Install the manifold air pressure (MAP) sensor and bracket. Refer to MAP Sensor Replacement in Powertrain Management.





13. Connect the vacuum hose at the manifold air pressure (MAP) sensor and the upper intake manifold.
14. Install the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid. Refer to Ignition Coil(s) Replacement and EVAP Canister Purge Valve Replacement in Powertrain Management.
15. Connect the thermostat bypass pipe coolant hoses to the throttle body.
16. Connect the wiring harness attachment clips.
^ Camshaft position (CMP) sensor wiring harness
^ Left spark plug wire harness
^ Engine wiring harness

17. Connect the left spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
18. Connect the wiring harness connectors to the throttle body.
^ Throttle position (TP) sensor
^ Idle air control (IAC) valve

19. Install the accelerator control and cruise control cables with bracket to the throttle body. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
20. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
21. Install the throttle body air inlet duct.
22. Connect the wiring harness connection to the intake air temperature (IAT) sensor in the throttle body air inlet duct. Refer to IAT Sensor Replacement in Powertrain Management.
23. Connect the vacuum hose connection to the throttle body air inlet duct.
24. Connect the battery ground (negative) cable. Refer to Refer to Battery Negative Cable Disconnect/Connect Procedure.