Upper

UPPER

1. If removed, install the throttle body to the upper intake manifold Throttle Body - Installation.

2. If removed, install the Manifold Air Pressure (MAP) sensor to the upper intake manifold Installation.

3. If removed, install the the brackets (1) to the upper intake manifold with bolts (2) tightened to 8 Nm (71 in. lbs.).

4. If removed, install the rear insulation pad (1) with push-pins (2) to the upper intake manifold.





NOTE:
Prior to installing the upper intake manifold, verify that the four fuel rail bolts were not inadvertently loosened. The bolts must tightened in the sequence shown to 7 Nm (62 in. lbs.). Fuel Rail - Installation .






5. Clean and inspect the sealing surfaces. Install new upper to lower intake manifold seals (1).

NOTE:
Make sure the fuel injectors and wiring harnesses are in the correct position so that they don't interfere with the upper intake manifold installation.

6. If removed, install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.





7. Lift and hold the seven upper intake attaching bolts (1) clear of the mating surface. Back the bolts out slightly or if required, use an elastic band to hold the bolts clear of the mating surface.

8. Position the upper intake manifold (1) onto the lower intake manifold so that the two locating posts (2) on the upper intake manifold align with corresponding holes (3) in the lower intake manifold.





9. Install the seven upper intake manifold attaching bolts. Tighten the bolts in the sequence shown to 8 Nm (71 in. lbs.).

NOTE:





10. Engage the wire harness retainer (1) to the upper intake manifold.

11. Engage the wire harness connector retainer (2) to the right upper intake manifold support bracket.

12. Engage the following hoses to the upper intake manifold:

- Fresh air makeup (4)

- Positive Crankcase Ventilation (PCV) (5)

- Transfer case vent (3)





13. Install the left rear upper intake manifold support bracket (1) with two nuts (2) tightened to 10 Nm (89 in. lbs.).

14. Tighten the two studbolts (3) to the left rear upper intake manifold support bracket (1) to 20 Nm (177 in. lbs.).





15. Position the wire harness and engage the wire harness retainers (2) to the left rear upper intake manifold support bracket.

16. Engage the brake booster hose retainer (1) to the left rear upper intake manifold support bracket.





17. Install the left front upper intake manifold support bracket (1) with two nuts (2) and two bolts (3). Tighten the nuts (2) to 10 Nm (89 in. lbs.) and tighten the bolts (3) to 10 Nm (89 in. lbs.).





18. Connect the following hoses to the upper intake manifold:

- Positive Crankcase Ventilation (PCV) (1)

- Vapor purge (3)

- Brake booster (2)





19. Position the wire harness and connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (6).

20. Engage the ETC harness to the clip (5) on the throttle body.

21. Engage the wire harness retainer (2) to the upper intake manifold.

22. Engage the wire harness retainers (3 and 4) to the left front upper intake manifold support bracket.






23. Install the air intake resonator to the throttle body. Hand tighten the clamp.
24. Connect the IAT sensor electrical connector (2).





25. Install the breather hose (1) to the air intake resonator (2).





26. Install the air intake hose (1) to the resonator.
27. Install the air cleaner cover (2).

28. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).