Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure

1. Turn the ignition OFF.
2. Remove the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair).
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027)).
4. Remove the fuel pressure and evaporative emission (EVAP) hoses from the engine. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) and Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




5. Remove the purge line from the purge line retainer.




6. Remove the fuel feed hose bracket bolt and reposition the fuel feed hose.

Important:
* Do not disconnect the engine control module (ECM) electrical connectors.

* Do not remove the ECM from the ECM bracket.


7. Remove the ECM bracket with the ECM and reposition aside. Refer to Engine Control Module Replacement (Service and Repair).




8. Disconnect the purge solenoid electrical connector.




9. Remove the wiring harness from the right side of the intake manifold.




10. Disconnect the fuel injector electrical connector.
11. Remove the fuel injector electrical connector from the fuel injector electrical connector bracket.




12. Remove the throttle body electrical connector.
13. Remove the brake booster vacuum hose and check valve from the brake booster.
14. Remove the electrical connector for the baro sensor.




15. Remove the positive crankcase ventilation (PCV) hose from the intake manifold.




16. Remove the intake manifold bolts (1-6).




17. Remove the upper intake manifold.
18. Remove and discard the upper intake manifold gasket.
19. Disassemble the intake manifold if necessary. Refer to Intake Manifold Disassemble (Overhaul).
20. Clean and inspect the intake manifold and the sealing surfaces. Refer to Intake Manifold Cleaning and Inspection (Overhaul).

Installation Procedure

1. Assemble the intake manifold if necessary. Refer to Intake Manifold Assemble (Overhaul).




2. Install the intake manifold.





Notice: Refer to Fastener Notice (Fastener Notice).

3. Install the intake manifold bolts (1-6).

Tighten the intake manifold bolts in the order shown to 23 N.m (17 lb ft).




4. Install the PCV hose to the intake manifold.
5. Install the brake booster vacuum hose and check valve to the brake booster.




6. Install the throttle body electrical connector.
7. Reconnect the electrical connector for the baro sensor.
8. Install the fuel injector electrical connector to the fuel injector electrical connector bracket.




9. Connect the fuel injector electrical connector.




10. Install the wiring harness and bracket to the right side of the intake manifold.

Tighten the wiring harness bracket bolts to 10 N.m (89 lb in).




11. Connect the purge solenoid electrical connector.
12. Install the ECM bracket with the ECM. Refer to Engine Control Module Replacement (Service and Repair).




13. Install the fuel feed hose bracket and the fuel feed hose bracket bolt.

Tighten the fuel feed hose bracket bolt to 10 N.m (89 lb in).




14. Install the purge line to the purge line retainer.
15. Install the fuel pressure and EVAP hoses to the engine. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) and Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
16. Install the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair).