Upper Intake Manifold Replacement

Removal Procedure





1. Disconnect the battery negative cable. Refer to Battery Cable.
2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
4. Remove the vacuum brake booster hose, if equipped.
5. Disconnect the accelerator control and cruise control cables (if equipped). Refer to Accelerator Controls Cable Replacement.
6. Remove the accelerator control cable bracket and set it aside.
7. Remove the following electrical connectors:
8. Remove the PCV tube at the intake manifold. Twist to unlock the PCV tube.





9. Remove the engine wiring harness bracket from the manifold.
10. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement.





11. Remove the studs holding the upper intake manifold to the lower intake manifold.
12. Remove the lower intake manifold. Refer to Intake Manifold Replacement (Lower).
13. Clean all the surfaces.


Installation Procedure





1. Install the lower intake manifold. Refer to Intake Manifold Replacement (Lower).
2. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the engine wiring harness bracket to the upper intake manifold.
- Tighten the nut to 12 Nm (106 inch lbs.).
4. Install the PCV valve hose assembly.
5. Install the distributor cap. Refer to Distributor Replacement.





6. Connect the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
7. Install the AIR check valve (crossover) pipe, if so equipped. Refer to Secondary Air Injection Check Valve/Pipe Replacement.
8. Connect the following electrical connectors.
- The SCPI injector harness connector. Refer to Fuel Meter Body Assembly Replacement.
- The EVAP canister purge solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement.
- The ignition coil. Refer to Ignition Coil and ICM Replacement (HVS).
- The Ignition Control Module (ICM). Refer to Vehicle Control Module Description.
- The generator. Refer to Generator Replacement.
- The Idle Air Control (IAC) motor. Refer to IAC Valve Replacement.
- The Throttle Position (TP) sensor. Refer to TP Sensor Replacement.
- The Oxygen (02) sensor. Refer to Heated Oxygen Sensor (HO2S) Replacement.
- The Exhaust Gas Recirculation (EGR) valve. Refer to EGR Valve Replacement.
- The Engine Coolant Temperature (ECT) sensor. Refer to Engine Coolant Temperature (ECT) Sensor Replacement.
- The engine oil pressure sensor
- Disconnect the fuel pipes from the fuel pipes. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
- Remove the AIR check valve (crossover) pipe, if equipped. Refer to Secondary Air Injection Check Valve/Pipe Replacement.
- Remove the distributor cap and reposition the distributor cap out of the way. Refer to Distributor Replacement.
9. Install the accelerator control cable bracket.
10. Connect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement.





11. Install the vacuum brake booster hose, if equipped.
12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
13. Connect the battery negative cable. Refer to Battery Cable.