Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure




1. Remove the fuel injector sight shield.
2. Remove the air cleaner outlet duct.
3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail.
4. Remove the fuel feed pipe line nut (2) and remove the fuel feed line clip from the stud.
5. Reposition the fuel feed line out of the way.




6. Remove the coolant air bleed hose/pipe clip bolt (3) from the upper intake manifold.
7. Reposition the coolant air bleed hose clamp (2) at the water outlet.
8. Remove the coolant air bleed hose from the water outlet.
9. Remove the coolant air bleed hose/pipe clip from the upper intake manifold stud and reposition out of the way.




10. Reposition the brake booster vacuum hose clamp (1) at the upper intake manifold.
11. Remove the brake booster vacuum hose (2) from the upper intake manifold.




12. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
13. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control (ETC).




14. Disconnect the engine wiring harness electrical connector (1) from the intake manifold tuning valve.
15. Disconnect the engine wiring harness electrical connector (2) from the evaporative emission (EVAP) canister purge solenoid.




16. Disconnect the positive crankcase ventilation (PCV) tube from the upper intake manifold and reposition aside.




17. Disconnect the EVAP canister purge solenoid tube quick connect fitting (1) at the upper intake manifold and reposition aside.




18. Remove the fuel rail to bracket bolt (1).




19. Remove the fuel rail wiring harness electrical connector bolt (2) and reposition the harness out of the way.
20. Remove the upper intake bolts (1).




21. Remove the upper intake manifold and gaskets. Discard gaskets.
22. If replacing the upper intake manifold complete the following steps:

1. Remove the MAP sensor.
2. Remove the throttle body.
3. Remove the EVAP canister purge solenoid valve.
4. Remove the intake manifold tuning valve.

Installation Procedure




1. If the upper intake manifold was replaced complete the following steps:

1. Install the MAP sensor.
2. Install the throttle body.
3. Install the EVAP canister purge solenoid valve.
4. Install the intake manifold tuning valve.

2. Place NEW upper intake manifold gaskets onto the lower intake manifold.
3. Place the upper intake manifold onto the lower intake manifold.





Notice: Refer to Fastener Notice .

4. Install the upper intake bolts (1).

Tighten the bolts to 23 N.m (17 lb ft).

5. Position the fuel rail wiring harness and install the fuel rail wiring harness electrical connector bolt (2).

Tighten the bolt to 10 N.m (89 lb in).




6. Install the fuel rail to bracket bolt (1).

Tighten the bolt to 10 N.m (89 lb in).




7. Position and install the EVAP canister purge solenoid tube quick connect fitting (1) to the upper intake manifold.




8. Position and install the PCV tube to the upper intake manifold.




9. Connect the engine wiring harness electrical connector (2) to the EVAP canister purge solenoid.
10. Connect the engine wiring harness electrical connector (1) to the intake manifold tuning valve.




11. Connect the engine wiring harness electrical connector (2) to the ETC.
12. Connect the engine wiring harness electrical connector (1) to the MAP sensor.




13. Install the brake booster vacuum hose (2) to the upper intake manifold.
14. Position the brake booster vacuum hose clamp (1) at the upper intake manifold.




15. Position and install the coolant air bleed hose/pipe clip to the upper intake manifold stud.
16. Install the coolant air bleed hose to the water outlet.
17. Position the coolant air bleed hose clamp (2) at the water outlet.
18. Install the coolant air bleed hose/pipe clip bolt (3) to the upper intake manifold.

Tighten the bolt to 10 N.m (89 lb in).




19. Position the fuel feed line and install the fuel feed line clip to the stud.
20. Install the fuel feed line nut (2).

Tighten the nut to 10 N.m (89 lb in).

21. Connect the fuel feed line (1) quick connect fitting to the fuel rail.
22. Install the air cleaner outlet duct.
23. Install the fuel injector sight shield.