Intake Manifold Replacement (Upper)

REMOVAL
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Remove the air cleaner box and intake duct.
4. Remove the wiring harness connectors and brackets and move aside.
5. Remove the throttle linkage and cruise control cable (if equipped).
6. Remove the fuel lines and bracket at the rear of the lower intake manifold.
7. Remove the PCV hose at the upper intake manifold.
8. Remove the ignition coil and bracket.
9. Remove the purge solenoid and bracket.

NOTE: Mark the location of all the studs for proper reassembly.

10. Remove the upper intake manifold bolts and studs.
11. Remove the upper intake manifold.
12. Clean old pieces of gasket form the gasket surfaces.
13. Inspect the manifold for cracks, broken flanges, and gasket surface damage.

INSTALLATION





1. Install the upper intake manifold gasket.





2. Install the upper intake manifold. Use care not to pinch the injector lines between the upper and lower intake manifolds.
3. Install the upper intake manifold bolts. Note the marks made at disassembly for proper stud location. Install the two corner studs first in order to help align the two halves.
- Tighten the bolts first pass 5 Nm (44 inch lbs.).
- Tighten the bolts final pass 10 Nm (88 inch lbs.).

4. Install the purge solenoid and bracket.
5. Install the ignition coil and bracket.
6. Install the PCV hose at the upper intake manifold.
7. Install the fuel lines and bracket at the rear of the lower intake manifold.
8. Install the throttle linkage and cruise control cable (if equipped).
9. Install the wiring harness connectors and brackets.
10. Install the air cleaner box and intake duct.
11. Install the engine cover.
- Connect the negative battery cable.
- Fill the cooling system if necessary.