Upper Intake Manifold Replacement

Removal Procedure





1. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Remove the Engine Cover. Refer to Engine Cover Replacement.
3. Remove the air intake duct from the throttle body. Refer to Air Cleaner Assembly Replacement.
4. Remove the air cleaner assembly from vehicle. Refer to Air Cleaner Assembly Replacement.
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. Refer to Exhaust Gas Recirculation (EGR) Pipe Replacement.
8. Remove the ignition coil from the intake manifold. Refer to Ignition Coil and ICM 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 Evaporative Emission (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 from the lower intake manifold.
14. Clean the excessive carbon deposit from the exhaust and the EGR valve passages.


Installation Procedure





1. Install the upper intake manifold and gaskets to the lower intake manifold.

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

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





Notice: Refer to Fastener Notice in Service Precautions.

3. Install the upper intake manifold bolts and tighten in the following manner.
^ Tighten the bolts in sequence to 8 Nm (72 inch lbs.).
^ Retighten the bolts in sequence to 18 Nm (13 ft. lbs.).
4. Install the number 8 spark plug wire. Refer to Spark Plug Wire Harness Replacement.
5. Install the ignition coil to the upper intake manifold. Refer to Ignition Coil and ICM Replacement.
6. Install the EGR valve if necessary. Refer to Exhaust Gas Recirculation (EGR) Valve Replacement.





7. Install the EGR pipe to the upper intake manifold. Refer to Exhaust Gas Recirculation (EGR) Pipe Replacement.
^ Tighten EGR valve fittings to 60 Nm (46 ft. lbs.).
8. Install the EVAP canister solenoid valve to the intake manifold. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
9. Install the throttle body to the upper intake manifold. Refer to Throttle Body Assembly Replacement.





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





11. Install the crankcase vent tube to the valve rocker arm cover.
12. Install the air intake duct to the throttle body. Refer to Air Cleaner Assembly Replacement.
13. Connect the battery negative cables to the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure.
14. Install Engine Cover. Refer to Engine Cover Replacement.