Upper Intake Manifold

Upper Intake Manifold

Special Tool(s):

Material:

Removal

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Drain the cooling system.
4. Remove the cowl panel grille.





5. Disconnect the windshield wiper motor electrical connector.





6. Remove the bolts and the cowl top panel.
7. Remove the engine air cleaner outlet pipe.
8. Disconnect the accelerator cable from the throttle body.
9. Disconnect the throttle return spring from the accelerator cable bracket.
10. Disconnect the speed control cable from the throttle body.
11. Detach the engine harness retainers from the accelerator cable bracket stud bolt and the throttle position (TP) sensor stud bolt.
12. Remove the 2 cable bracket stud bolts and position aside the cable bracket.
13. Disconnect the evaporative emission (EVAP) return tube from the intake manifold.
14. Disconnect the brake booster vacuum hose from the intake manifold.
15. Disconnect the upper and lower exhaust gas recirculation (EGR) system module tube fittings and remove the tube.
16. Disconnect the EGR system module vacuum connector.
17. Disconnect the EGR system module electrical connector.
18. Disconnect the idle air control (IAC) valve electrical connector.
19. Disconnect the TP sensor electrical connector.
20. Disconnect the crankcase vent hose from the intake manifold.

21. CAUTION: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.

CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.





With a twisting motion, use the special tool to pull the LH spark plug wires from the spark plugs and the ignition coil.
22. Remove the LH pin-type retainers and the spark plug wires as an assembly.
23. Disconnect the upper intake manifold vacuum tube connector.
24. Disconnect the coolant inlet hose clamp and the coolant hose from the intake manifold.
25. Disconnect the coolant outlet hose clamp and the coolant hose from the intake manifold.
26. Remove the 8 upper intake manifold bolts.





27. Disconnect the 4 engine harness pin-type retainers.





28. Disconnect the 2 engine harness pin-type retainers.
29. Remove the intake manifold and discard the intake manifold gaskets.

Installation
1. Install new intake manifold gaskets and position the intake manifold.





2. Install the 8 intake manifold bolts and tighten the upper intake manifold bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 6 Nm (53 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).





3. Connect the 2 engine harness pin-type retainers.





4. Connect the 4 engine harness pin-type retainers.
5. Connect the coolant outlet hose to the intake manifold.
6. Connect the coolant inlet hose to the intake manifold.
7. Connect the vacuum tube connector to the upper intake manifold.

8. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold.

NOTE: Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs and the ignition coil.

Install the spark plug wires and pin-type retainers as an assembly.
9. Connect the crankcase vent hose to the intake manifold.
10. Connect the TP sensor electrical connector.
11. Connect the IAC valve electrical connector.
12. Connect the EGR system module electrical connector.
13. Connect the EGR system module vacuum connector.
14. Position the EGR system module tube and connect the upper and lower module tube fittings.
^ Tighten to 40 Nm (30 ft. lbs.).
15. Connect the brake booster vacuum hose to the intake manifold.
16. Connect the EVAP return tube to the intake manifold.
17. Position the accelerator cable bracket and install the 2 stud bolts.
^ Tighten to 10 Nm (89 inch lbs.).
18. Attach the engine harness retainers to the accelerator cable bracket stud bolt and the TP sensor stud bolt.
19. Connect the speed control cable to the throttle body.
20. Connect the throttle return spring to the accelerator cable bracket.
21. Connect the accelerator cable to the throttle body.
22. Install the engine air cleaner outlet pipe.





23. Install the cowl top panel and the bolts.
^ Tighten to 6 Nm (53 inch lbs.).





24. Connect the windshield wiper motor electrical connector.
25. Install the cowl panel grille.
26. Fill and bleed the cooling system.
27. Connect the battery ground cable.