Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure




1. Remove the air cleaner outlet duct.
2. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement (Service and Repair).
3. Remove the brake booster vacuum hose from the upper intake manifold fitting.




4. Disconnect the evaporative emission (EVAP) pipe quick connect fitting (2) from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




5. Remove the engine wiring harness heat shield nut and bolt.
6. Remove the engine wiring harness heat shield.




7. Remove the upper intake manifold bolts and studs.
8. Remove the upper intake manifold.




9. If replacing the intake manifold perform the following steps, otherwise proceed to step 10 in the installation procedure.
10. Disengage the retainers and remove the manifold absolute pressure (MAP) sensor.




11. Remove the EVAP purge solenoid bolt and solenoid.




12. Loosen the throttle body upper bolts.
13. Remove the throttle body lower nuts.
14. Remove the throttle body.




15. Squeeze the sides of the vacuum fitting in order to disengage the retainers and remove the vacuum fitting.
16. Remove and discard the O-ring seal.




17. Remove the intake manifold gasket carrier from the upper intake manifold.

Installation Procedure




1. If replacing the intake manifold perform the following steps, otherwise proceed to 10.
2. Install a the intake manifold gasket carrier to the upper intake manifold.




3. Install a NEW vacuum fitting O-ring seal.
4. Squeeze the sides of the vacuum fitting in order to install the vacuum fitting.




5. Install the throttle body.
6. Tighten the throttle body upper bolts.

Notice: Refer to Fastener Notice (Fastener Notice).

7. Install the throttle body lower nuts.

Tighten the bolts/nuts to 10 N.m (89 lb in).




8. Install the EVAP purge solenoid and bolt.

Tighten the bolt to 10 N.m (89 lb in).




9. Install the MAP sensor.




10. Install the upper intake manifold.
11. Install the upper intake manifold bolts and studs.




12. Tighten the upper intake manifold bolts and studs in the sequence shown.

Tighten the bolts/studs to 10 N.m (89 lb in).




13. Install the engine wiring harness heat shield.
14. Install the engine wiring harness heat shield nut and bolt.

Tighten the bolt/nut to 10 N.m (89 lb in).




15. Connect the EVAP pipe quick connect fitting (2) to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




16. Install the brake booster vacuum hose to the upper intake manifold fitting.
17. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement (Service and Repair).
18. Install the air cleaner outlet duct.