Upper

Upper Intake Manifold

Removal
1. Disconnect the battery ground cable.
2. Remove the engine air cleaner outlet pipe.





3. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.





4. Disconnect the throttle position (TP) sensor electrical connector and the evaporative emissions (EVAP) return tube.





5. Disconnect the accelerator and the speed control cables from the throttle body cam.





6. Remove the bolts and position the accelerator cable bracket assembly aside.





7. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system electrical and vacuum connections.





8. Disconnect the EGR vacuum regulator solenoid electrical and vacuum connections.





9. Disconnect the positive crankcase ventilation (PCV) tube.





10. Disconnect the vacuum hoses.





11. Disconnect the following:
- Ignition coil electrical connector.
- Radio interference capacitor electrical connector.
- Spark plug wires.





12. Disconnect the vacuum hose.





13. NOTE: For ease in installation, record the location of the long bolts and the short bolts.

Remove the upper intake manifold.
1. Remove the 12 bolts.
2. Remove the upper intake manifold.





14. Remove and discard the upper intake manifold gasket.

Installation





1. Install a new upper intake manifold gasket.





2. NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct locations.

Install the upper intake manifold. Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 10 Nm (89 inch lbs.).
- Stage 2: Rotate an additional 90 degrees (1/4 turn).





3. Connect the vacuum hose.





4. Connect the following:
- Ignition coil electrical connector.
- Radio interference capacitor electrical connector.
- Spark plug wires.





5. Connect the vacuum hoses.





6. Connect the PCV tube.





7. Connect the differential pressure feedback EGR system electrical and vacuum connections.





8. Connect the EGR vacuum regulator solenoid electrical and vacuum connections.





9. Position the accelerator cable bracket and install the bolts.





10. Connect the accelerator and speed control cables to the throttle body cam.





11. Connect the EVAP return tube and the TP sensor electrical connector.





12. Connect the vacuum hose and the IAC valve electrical connector.
13. Install the engine air cleaner outlet pipe.
14. Connect the battery ground cable.