Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure




1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Battery Negative Cable Disconnection and Connection).
2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (Intake Manifold Cover Replacement).
3. Drain the cooling system. Refer to Cooling System Draining and Filling (Cooling System Draining and Filling).
4. Remove the positive crankcase ventilation (PCV) fresh air tube. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




5. Remove the PCV foul air tube. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




6. Remove the brake booster vacuum hose from the intake manifold fitting.




7. Reposition the heater inlet and outlet hose/pipe clamps at the engine pipes.
8. Remove the heater inlet and outlet hose/pipe clamp nuts from the throttle body studs.
9. Remove the heater inlet and outlet hoses/pipes from the engine pipes and the throttle body studs.
10. Reposition the hoses/pipes out of the way.




11. Remove the fuel line and evaporative emission (EVAP) line clip from the manifold absolute pressure (MAP) sensor bracket.
12. Disconnect the MAP sensor electrical connector (1).




13. Disconnect the EVAP canister purge solenoid electrical connector (1).
14. Disconnect the chassis EVAP line quick connect fitting from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
15. Disconnect the electronic throttle control (ETC) electrical connector (2).




16. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Service and Repair).
17. Disconnect the left side spark plug wires from the spark plugs.
18. Disconnect the left side spark plug wires from the ignition coil.
19. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
20. Remove the left side spark plug wires.




21. Remove the throttle body bolts and nuts.
22. Remove the throttle body and gasket.
23. If installing a replacement manifold, remove the throttle body-to-manifold studs.




24. Remove the EVAP canister purge solenoid valve bolt.
25. Remove the EVAP canister purge solenoid valve.




26. Remove the ignition coil bracket to intake manifold bolts.
27. Loosen power steering reservoir to intake manifold bolt and reposition.
28. Remove generator to intake manifold bracket bolt.
29. Remove the intake manifold cover ball stud nut from the intake manifold stud.
30. Remove the upper intake manifold bolts and stud.
31. Separate and remove the upper intake manifold from the lower intake manifold.
32. Remove the upper to lower intake manifold gaskets.
33. Clean the upper intake to lower intake gasket mating surfaces.

Installation Procedure

1. Install the upper intake manifold onto the lower intake manifold.
2. Apply threadlock to the upper intake manifold bolts/stud threads. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the upper intake manifold bolts and stud and tighten the bolts to 25 Nm (18 lb ft).
4. Install the intake manifold cover ball stud nut to the intake manifold stud and tighten the nut to 5 Nm (44 lb in).
5. Install the ignition coil bracket to intake manifold bolts and tighten the bolts to 25 Nm (18 lb ft).




6. Install the MAP sensor and bracket.
7. Install the MAP sensor bracket/upper intake manifold bolts and tighten to 25 Nm (18 lb ft).




8. Install the EVAP canister purge solenoid valve.
9. Install the EVAP canister purge solenoid valve bolt and tighten to 16 Nm (12 lb ft).




10. Inspect the throttle body seal for damage. Replace as necessary.
11. Apply threadlock to the throttle body bolts/studs threads. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).
12. Position the throttle body gasket and throttle body to the intake.
13. Install the throttle body studs, if required and tighten to 6 Nm (53 lb in).
14. Install the throttle body bolts and nuts and tighten to 10 Nm (89 lb in).




15. Install the left side spark plug wires.
16. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
17. Connect the left side spark plug wires to the ignition coil.
18. Connect the left side spark plug wires to the spark plugs.
19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Service and Repair).




20. Connect the EVAP canister purge solenoid electrical connector (1).
21. Connect the chassis EVAP line quick connect fitting to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
22. Connect the ETC electrical connector (2).




23. Connect the MAP sensor electrical connector (1).
24. Install the fuel feed and EVAP line clip to the MAP sensor bracket.




25. Position the hoses/pipes.
26. Install the heater inlet and outlet hoses/pipes to the engine pipes and the throttle body studs.
27. Install the heater inlet and outlet hose/pipe clamp nuts to the throttle body studs and tighten the nuts to 10 Nm (89 lb in).
28. Position the heater inlet and outlet hose/pipe clamps at the engine pipes.




29. Install the brake booster vacuum hose to the intake manifold.




30. Install the PCV foul air tube. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




31. Install the PCV fresh air tube. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
32. Fill the cooling system. Refer to Cooling System Draining and Filling (Cooling System Draining and Filling).
33. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (Intake Manifold Cover Replacement).
34. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Battery Negative Cable Disconnection and Connection).