Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure




1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.
3. Remove the vacuum hoses from the following:

* Evaporative emissions (EVAP) canister purge valve
* Manifold vacuum source
* Brake booster
* Heater and air conditioning (A/C) source

4. Disconnect the electrical connectors from the following:

* Exhaust gas recirculation (EGR) valve
* Mass air flow (MAF) sensor
* Intake air temperature (IAT) sensor
* Electronic throttle control
* EVAP canister purge valve

5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
6. Remove the left side spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement Service and Repair.
7. Remove the following wiring harnesses from the retainers:

* Camshaft position (CMP) sensor wiring harness
* Left side spark plug wire harness
* Engine wiring harness




8. Remove the ignition coil bracket with the coils. Refer to Ignition Control Module Replacement Service and Repair.
9. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement Service and Repair.
10. Remove the manifold absolute pressure (MAP) sensor and the bracket. Refer to Manifold Absolute Pressure Sensor Replacement Service and Repair.
11. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement Service and Repair.
12. Remove the upper intake manifold bolts and the stud.
13. Remove the upper intake manifold.
14. Remove the upper intake manifold gaskets.




15. If replacing the upper intake manifold, remove the throttle body. Refer to Throttle Body Assembly Replacement Removal and Replacement.
16. Clean the upper intake gasket mating surfaces.

Installation Procedure




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




2. Install the upper intake manifold gaskets.
3. Install the upper intake manifold.

Caution: Refer to Fastener Caution Fastener Caution.

4. Install the right upper intake manifold bolts and the stud.

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

5. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement Service and Repair.
6. Install the MAP sensor bracket and the sensor. Refer to Manifold Absolute Pressure Sensor Replacement Service and Repair.
7. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement Service and Repair.
8. Install the ignition coil bracket with the coils. Refer to Ignition Control Module Replacement Service and Repair.
9. Install the following wiring harnesses to the retainers:

* Engine wiring harness
* Left side spark plug wire harness
* CMP sensor wiring harness

10. Install the left side spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement Service and Repair.
11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
12. Connect the electrical connectors to the following:

* EVAP canister purge valve
* Electronic throttle control
* IAT sensor
* MAF sensor
* EGR valve




13. Install the vacuum hoses to the following:

* Heater and A/C source
* Brake booster
* Manifold vacuum source
* EVAP canister purge valve

14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
15. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.