Intake Manifold Replacement (Upper)

REMOVAL PROCEDURE





1. Open the hood.
2. Disconnect the battery negative cable from the battery.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

3. Remove the intake air resonator from the throttle body.
4. Remove the air cleaner intake duct from the throttle body.
5. Remove the crankcase vent tube from the throttle body.





6. Remove the PCV valve from the valve rocker arm cover.





7. Remove the EGR pipe from the upper intake manifold.
8. Remove the ignition coil from the intake manifold.
9. Remove the throttle body from the upper intake manifold.
10. Remove the EVAP canister solenoid valve.
11. Remove the number 8 spark plug wire from the distributor.





12. Remove the upper intake manifold bolts.
13. Remove the upper intake manifold and gaskets.
14. Clean the excessive carbon deposit from the exhaust and the EGR valve passages. Refer to Cylinder Head Clean and Inspect under Engine Unit Repair.

INSTALLATION PROCEDURE





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

IMPORTANT: Failure to follow the procedure listed, could cause a driveability problem.

3. Coat a minimum of eight threads of the bolts with thread locking sealant G/M P/N 12345493.





4. Install the upper intake manifold bolts.
4.1. Tighten the bolts in the following manner:
4.2. Tighten the bolts in sequence to 8 Nm (71 inch lbs.).
4.3. Re tighten the bolts in sequence to 18 Nm (13 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

5. Install the number 8 spark plug wire.
6. Install the ignition coil to the upper intake manifold.
7. Install the EGR valve if necessary.





8. Install the EGR pipe to the upper intake manifold.
Tighten EGR valve fittings to 60 Nm (46 ft. lbs.).

9. Install the EVAP canister solenoid valve to the intake manifold.
10. Install the throttle body to the upper intake manifold.





11. Install the PCV valve to the valve rocker arm cover to the cylinder head.





12. Install the crankcase vent tube to the valve rocker arm cover.
13. Install the air cleaner intake duct to the throttle body.
14. Install the intake air resonator to the throttle body.
15. Connect the battery negative cables to the battery.
16. Close the hood.