Upper Intake Manifold
Upper Intake ManifoldMaterial:
Upper Intake Manifold Attachments (Part 1):
Upper Intake Manifold Attachments (Part 2):
Vacuum, Electrical and PCV Connections:
Upper Intake Manifold:
Removal
1. Drain the engine cooling system. For additional information, refer to Cooling System.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
4. Remove the 2 bolts and position the heater hoses aside.
5. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark the spark plug wires for installation reference.
Disconnect the 3 LH spark plug wires from the ignition coil, disconnect the 2 spark plug wire retainers from the upper intake manifold and position the LH spark plug wires aside.
6. Disconnect the EGR system module electrical and vacuum connectors.
7. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module.
8. Disconnect the electronic throttle body (TB) electrical connector.
9. Release the clamp and disconnect the fuel vapor tube from the upper intake manifold.
10. Disconnect the 5 wiring harness retainers from the upper intake manifold.
11. Release the clamp and disconnect the brake booster vacuum hose from the upper intake manifold.
12. Disconnect the vacuum hose connector from the rear of the upper intake manifold.
13. Release the clamps and disconnect the 2 heated PCV coolant hoses from the rear of the upper intake manifold.
14. Disconnect the PCV valve hose from the rear of the upper intake manifold.
15. Detach the fuel charging wiring harness-to-main engine wiring harness electrical connector retainer from the rear of the upper intake manifold.
16. Remove the 8 bolts and the upper intake manifold.
Installation
1. Inspect the 6 upper intake manifold gaskets. Install new gaskets, if necessary.
2. Position the upper intake manifold and install the bolts. Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 6 Nm (53 lb-in).
^ Stage 2: Tighten to 10 Nm (89 lb-in).
3. Attach the fuel charging wiring harness-to-main engine wiring harness electrical connector retainer to the rear of the upper intake manifold.
4. Connect the PCV valve hose to the rear of the upper intake manifold.
5. Connect the 2 heated PCV coolant hoses to the rear of the upper intake manifold and position the clamps.
6. Connect the vacuum hose connector to the rear of the upper intake manifold.
7. Connect the brake booster vacuum hose to the upper intake manifold and position the clamp.
8. Connect the 5 wiring harness retainers to the upper intake manifold.
9. Connect the fuel vapor hose to the upper intake manifold and position the clamp.
10. Connect the electronic throttle body (TB) electrical connector.
11. Connect the exhaust manifold-to-EGR system module tube to the EGR system module.
^ Tighten to 40 Nm (30 lb-ft).
12. Connect the EGR system module electrical and vacuum connectors.
13. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug wire boots.
NOTE: Spark plug wires must be connected to the correct ignition coil terminals.
Position the spark plug wires, connect the 2 spark plug wire retainers to the upper intake manifold and connect the 3 spark plug wires to the ignition coil.
14. Position the heater hoses and install the bolt.
^ Tighten to 5 Nm (44 lb-in).
15. Install the air cleaner outlet pipe.
16. Connect the battery ground cable. For additional information, refer to Battery.
17. Fill and bleed the engine cooling system.