Intake Manifold Replacement (Upper)

REMOVAL PROCEDURE





1. Remove the air cleaner outlet duct from the throttle body.
2. Disconnect the hose fitting from the Evaporative Emission (EVAP) canister purge solenoid valve and move the hose aside.
3. Disconnect the following electrical connectors:
- The Throttle Position (TP) sensor
- The Idle Air Control (IAC) motor
- The fuel meter body assembly connector
- The Manifold Absolute Pressure (MAP) sensor
- The EVAP canister purge solenoid valve

4. Remove the engine wiring harness from the engine wiring harness bracket at the right rear of the engine.





5. Remove the nut and the ground wire from the stud for the engine wiring harness bracket at the rear of the right cylinder head.





6. Remove the stud at the rear of the right cylinder head and the nut from the EVAP canister purge solenoid valve holding the engine wiring harness bracket.
7. Remove the engine wiring harness bracket.





8. Remove the engine wiring harness nut and clip from the throttle body stud.





9. Remove the engine wiring harness from the engine wiring harness bracket at the left rear of the engine.
10. Move the engine wiring harness aside.





11. Remove the bracket for the engine wiring harness from the upper intake studs.





12. Remove the vacuum brake booster hose.





13. Remove the PCV valve hose assembly form the intake manifold and the valve rocker arm cover.
14. Remove the EVAP canister purge solenoid valve.





15. Disconnect the accelerator control cable from the throttle shaft and the accelerator cable bracket.
16. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket.
17. Remove the accelerator cable bracket from the throttle body and the intake manifold.
18. Remove the fuel lines from the fuel meter body assembly.





19. Remove the upper intake manifold. Refer to Intake Manifold Disassemble under Engine Unit Repair.
20. Clean all sealing surfaces. Refer to Intake Manifold Clean and Inspect under Engine Unit Repair.

INSTALLATION PROCEDURE





1. Install the upper intake manifold. Refer to Intake Manifold Assemble under Engine Unit Repair.
2. Install the fuel lines to the fuel meter body assembly.





3. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.





4. Install the vacuum brake booster hose to the intake manifold.
5. Install the EVAP canister purge solenoid valve.





6. Install the left side bracket for the engine wiring harness on the lower intake manifold studs.
7. Install the engine wiring harness bracket nuts.
Tighten the engine wiring harness bracket nuts to 12 Nm (106 inch lbs.).

Notice: Refer to Fastener Notice in Service Precautions.





8. Install the engine wiring harness to the engine wiring harness bracket at the left rear of the engine.





9. Install the engine wiring harness clip and nut to the throttle body stud.
Tighten the engine wiring harness clip nut to 10 Nm (88 inch lbs.).





10. Install the right side engine wiring harness bracket on the EVAP canister purge solenoid valve stud.
11. Install the stud and the nut for the engine wiring harness bracket.
- Tighten the engine wiring harness bracket nut to 10 Nm (88 inch lbs.).
- Tighten the engine wiring harness bracket stud to 25 Nm (18 ft. lbs.).





12. Install the ground wire and nut to the engine wiring harness bracket stud at the rear of the right cylinder head.
Tighten the ground wire nut to 8 Nm (71 inch lbs.).





13. Install the engine wiring harness to the engine wiring harness bracket at the right rear of the engine.
14. Connect the following electrical connectors:
- The throttle position (TP) sensor
- The idle air control (IAC) motor
- The fuel meter body assembly connector
- The manifold absolute pressure (MAP) sensor
- The EVAP canister purge solenoid valve

15. Install the accelerator control cable bracket to the throttle body and the intake manifold.
Tighten the accelerator control cable bracket studs and nuts to 12 Nm (106 inch lbs.).
16. Install the cruise control cable, if equipped to the throttle shaft and the bracket.
17. Install the accelerator control cable to the throttle shaft and the bracket.
18. Connect the hose fitting for the EVAP canister purge solenoid valve.
19. Install the air cleaner outlet duct to the throttle body assembly.