Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure




1. Remove the fuel pipes/hoses. Refer toFuel Line Replacement - Engine (Fuel Line Replacement - Engine).
2. Disconnect the following electrical connectors:

* The A/C pressure switch (1), if equipped
* The air conditioning (A/C) compressor clutch (2), if equipped




3. Disconnect the control port injector module (1).




4. Remove the engine wiring harness clips (1, 2) from the engine harness brackets.




5. Remove the engine wiring harness rear bracket bolts and bracket.




6. Disconnect the following electrical connectors:

* The evaporative emission (EVAP) canister purge solenoid valve (1)
* The manifold absolute pressure (MAP) sensor




7. Disconnect the evaporative emission (EVAP) canister purge solenoid valve tube quick connect fitting (1) from the EVAP purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
8. Reposition the tube out of the way.




9. Remove the engine wiring harness ground nut and ground wire from the rear of the right cylinder head.




10. Remove the stud (1) holding the engine wiring harness bracket.
11. Reposition the engine wiring harness with the bracket aside.




12. Remove the positive crankcase ventilation (PCV) valve hose from the valve and rocker cover.
13. Disconnect the power brake booster vacuum hose from the vacuum fitting.




14. Remove the intake manifold - upper studs.
15. Remove the front 2 throttle body studs.
16. Remove the intake manifold - upper.




17. Remove and discard the intake manifold - upper gasket.




18. Remove and discard the O-ring seal from the fuel meter body.




19. If required, remove the power brake booster vacuum fitting.
20. Remove and discard the O-ring seal.




21. If required, remove the PCV valve cover.
22. Remove and discard the O-ring seal.




23. If required, remove the rear throttle body stud.
24. Remove the throttle body.
25. Remove and discard the throttle body gasket.




26. If required, remove the MAP sensor.
27. Remove and discard the MAP sensor seal.




28. If required, remove the EVAP canister purge solenoid valve studs.
29. Remove the purge solenoid valve.
30. Clean and inspect the intake manifold - upper, if necessary. Refer to Intake Manifold Cleaning and Inspection (53. Intake Manifold Cleaning and Inspection).

Installation Procedure




1. If required, install the purge solenoid valve.
Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the EVAP canister purge solenoid valve studs. If reusing the old studs, apply threadlock to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.

Tighten the studs to 10 Nm (89 lb in).




3. If required, install a NEW MAP sensor seal. Apply a small drop of clean engine oil to the seal.
4. Install the MAP sensor.




5. If required, install a NEW throttle body gasket.
6. Install the throttle body.
7. Install the rear throttle body stud. If reusing the old stud, apply threadlock to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.

Tighten the stud to 9 Nm (80 lb in).




8. If required, install a NEW O-ring seal to the PCV cover. Apply clean engine oil to the seal.
9. Install the PCV valve cover.




10. If required, install a NEW O-ring seal. Apply clean engine oil to the seal.
11. Install the power brake booster vacuum fitting.




12. Install a NEW O-ring seal to the fuel meter body.




13. Install a NEW upper intake manifold gasket.




14. Install the intake manifold - upper.
15. If reusing the old throttle body/intake manifold studs, apply threadlock to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.
16. Install the front two throttle body studs.
17. Install the intake manifold - upper studs.

Tighten the studs to 9 Nm (80 lb in).

18. Connect the power brake booster vacuum hose to the vacuum fitting.




19. Install the PCV valve hose to the valve cover and rocker cover.




20. Position the engine wiring harness and bracket.
21. Install the engine wiring harness bracket stud (1).

Tighten the stud to 25 Nm (18 lb ft).

22. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.

Tighten the nut to 9 Nm (80 lb in).




23. Install the engine wiring harness ground nut and ground wire to the rear of the right cylinder head.

Tighten the nut to 16 Nm (12 lb ft).




24. Position the EVAP canister purge solenoid tube, and connect the tube quick connect fitting (1) to the EVAP purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




25. Connect the following electrical connectors:

* The EVAP canister purge solenoid valve (1)
* The MAP sensor




26. Place the engine wiring harness rear bracket onto the upper intake manifold and install the bolts.

Tighten the bolts to 10 Nm (89 lb in).




27. Install the engine wiring harness clips (1, 2) to the engine harness brackets.




28. Connect the control port injector module (1).




29. Connect the following electrical connectors:

* The A/C compressor clutch (2), if equipped
* The A/C pressure switch (1), if equipped

30. Install the fuel pipes/hoses. Refer to Fuel Line Replacement - Engine (Fuel Line Replacement - Engine).