Upper Intake Manifold Replacement

Removal Procedure





1. Disconnect the battery ground (negative) cable. Refer to Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Disconnect the vacuum hose connection from the throttle body air inlet duct.
3. Disconnect the wiring harness connection from the intake air temperature (IAT) sensor in the throttle body air inlet duct. Refer to MT Sensor Replacement.
4. Remove the throttle body air inlet duct.
5. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
6. Remove the accelerator control and cruise control cables with bracket from the throttle body. Refer to Accelerator Controls Cable Replacement.
7. Disconnect the wiring harness connectors from the throttle body.
^ Throttle position (TP) sensor
^ Idle air control (IAC) valve
8. Disconnect the (left) front spark plug wires. Refer to Spark Plug Wire Harness Replacement.
9. Disconnect the wiring harness attachment clips.
^ Camshaft position (CMP) sensor wiring harness
^ left spark plug wire harness
^ Engine wiring harness
10. Disconnect the thermostat bypass pipe coolant hoses from the throttle body.
11. Remove the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid. Refer to Ignition Coil(s) Replacement and EVAP Canister Purge Valve Replacement.
12. Disconnect the vacuum hose at the manifold air pressure (MAP) sensor and upper intake manifold.
13. Remove the manifold air pressure (MAP) sensor and the bracket. Refer to MAP Sensor Replacement.





14. Disconnect the emission control vacuum harness.
15. Disconnect the vacuum hose connections from the upper intake manifold.
^ Vacuum booster hose
^ Automatic transaxle vacuum modulator hose
^ Heater and air conditioning vacuum source hose
^ Fuel pressure regulator
16. Remove the generator brace. Refer to Generator Brace Replacement.





17. Remove the exhaust gas recirculation (EGR) valve. Refer to EGR Valve Replacement.





18. Remove the right upper intake manifold bolts and studs.





19. Remove the left upper intake manifold bolts.
20. Remove the upper intake manifold.





21. Remove the upper intake manifold gasket.





22. If replacing the upper intake manifold, remove the throttle body. Refer to Throttle Body Assembly Replacement.
23. Clean the seal surfaces on the manifold with degreaser.

Installation Procedure





1. If removed, install the throttle body. Refer to Throttle Body Assembly Replacement.





2. Install the upper intake manifold gasket.





3. Install the upper intake manifold.
4. Loosely install the left upper intake manifold bolts.





5. Loosely install the right upper intake manifold bolts and studs.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the upper intake manifold bolts and studs.
^ Tighten the upper intake manifold bolts and studs to 25 Nm (18 ft. lbs.).





7. Install the exhaust gas recirculation (EGR) valve. Refer to EGR Valve Replacement.
8. Install the generator brace. Refer to Generator Brace Replacement.
9. Connect the vacuum hose connections to the upper intake manifold.
^ Vacuum booster hose
^ Automatic transaxle vacuum modulator hose
^ Heater and air conditioning vacuum source hose
^ Fuel pressure regulator





10. Connect the emission control vacuum harness.
11. Install the manifold air pressure (MAP) sensor and bracket. Refer to MAP Sensor Replacement.





12. Connect the vacuum hose at the manifold air pressure (MAP) sensor and the upper intake manifold.
13. Install the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid. Refer to Ignition Coil(s) Replacement and EVAP Canister Purge Valve Replacement.
14. Connect the thermostat bypass pipe coolant hoses to the throttle body.
15. Connect the wiring harness attachment clips.
^ Camshaft position (CMP) sensor wiring harness
^ left spark plug wire harness
^ Engine wiring harness
16. Connect the left spark plug wires. Refer to Spark Plug Wire Harness Replacement.
17. Connect the wiring harness connectors to the throttle body.
^ Throttle position (TP) sensor
^ Idle air control (IAC) valve
18. Install the accelerator control and cruise control cables with bracket to the throttle body. Refer to Accelerator Controls Cable Replacement.
19. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
20. Install the throttle body air inlet duct.
21. Connect the wiring harness connection to the intake air temperature (IAT) sensor in the throttle body air inlet duct. Refer to MT Sensor Replacement.
22. Connect the vacuum hose connection to the throttle body air inlet duct.
23. Connect the battery ground (negative) cable. Refer to Refer to Battery Negative Cable Disconnect/Connect Procedure.