Upper Intake Manifold Replacement

Removal Procedure






1. Disconnect the battery negative cable from the battery. Refer to Battery Cable.
2. Remove the intake air resonator from the throttle body. Refer to Air Cleaner Element Replacement.
3. Remove the air cleaner intake duct from the throttle body. Refer to Air Air Cleaner Assembly Replacement.






4. Remove the crankcase vent tube from the throttle body.






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






6. Remove the EGR pipe from the upper intake manifold. Refer to EGR Pipe Replacement.
7. Remove Left and Right Side Secondary AIR Injection Pipe. If so Equipped. Refer to Secondary Air Injection Check Valve/Pipe Replacement.
8. Remove the ignition coil from the intake manifold. Refer to Ignition Coil and 1CM Replacement.
9. Remove the throttle body from the upper intake manifold. Refer to Throttle Body Assembly Replacement.
10. Remove the EVAP canister solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement.
11. Remove the number 8 spark plug wire from the distributor. Refer to Spark Plug Wire Harness Replacement.






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.


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.






Notice: Refer to Fastener Notice in Service Precautions.

4. Install the upper intake manifold bolts.
4.1. Tighten the bolts in sequence to 8 Nm (71 in. lbs.).
4.2. Re tighten the bolts in sequence to 18 Nm (13 ft. lbs.).
5. Install the number 8 spark plug wire. Refer to Spark Plug Wire Harness Replacement (7.4 L).
6. Install the ignition coil to the upper intake manifold. Refer to Ignition Coil and ICM Replacement.
7. Install the EGR valve if necessary. Refer to Secondary Air Injection Check Valve/Pipe Replacement.






8. Install the EGR pipe to the upper intake manifold.
^ Tighten EGR valve fittings to 60 Nm (46 ft. lbs.).
9. Install Left and Right Side Secondary AIR Injection Pipes. If so equipped. Refer to Secondary Air Injection Check Valve/Pipe Replacement.
10. Install the EVAP canister solenoid valve to the intake manifold. Refer to EVAP Canister Purge Solenoid Valve Replacement
11. Install the throttle body to the upper intake manifold. Refer to Throttle Body Assembly Replacement.






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






13. Install the crankcase vent tube to the valve rocker arm cover.
14. Install the air cleaner intake duct to the throttle body. Refer to Air Cleaner Assembly Replacement.
15. Install the intake air resonator to the throttle body. Refer to Air Cleaner Element Replacement.
16. Connect the battery negative cables to the battery. Refer to Battery Cable.