Upper

Intake Manifold -Upper

Removal
1. Remove the air cleaner outlet tube.
2. Partially drain the engine cooling system.





3. Remove the three bolts and the engine appearance cover.





4. Disconnect the accelerator cable, speed control cable, and the return spring.





5. Remove the bolts and position the cables and bracket out of the way.





6. Disconnect the evaporative emission (EVAP) return line.





7. Disconnect and remove the positive crankcase ventilation (PCV) tube.





8. Disconnect the coolant lines and plug.





9. Disconnect the electrical connector from the intake tuning valve.





10. Remove the bolts and five clips and the wiring harness shield.





11. Remove the bolts and the stud, and the balance tube.





12. Remove and discard the gaskets and clean the sealing surfaces.





13. Disconnect the throttle position (TP) sensor.





14. Disconnect the idle air control (IAC) motor.





15. Disconnect the vacuum lines and the electrical connector from the EGR vacuum regulator (EVR).





16. Disconnect the two hoses and the electrical connector from the differential pressure feedback EGR sensor.





17. Remove the nut.





18. NOTE: The bolts are located at the front side of the LH cylinder head.

Remove the bolts from the power steering reservoir bracket and position it aside.





19. Remove the stud and position the oil fill tube aside.





20. Disconnect the brake booster vacuum line.





21. Disconnect the vacuum line.





22. Disconnect the vacuum line from the exhaust gas recirculation (EGR) valve.





23. Remove the bolts from the EGR adapter.





24. Remove the bolts and the upper intake manifold.
^ Clean and inspect the sealing surfaces.

Installation





1. Install the upper intake manifold:
^ Install the bolts.
^ Tighten the bolts to 10 Nm (89 inch lbs.) and then an additional 90 degrees in the sequence shown.





2. Install the EGR adapter.
^ Install a new gasket.
^ Position the EGR valve adapter.
^ Install the bolts.





3. Connect the vacuum line to the EGR valve.





4. Connect the vacuum line.





5. Connect the brake booster vacuum line.





6. Position the oil fill tube and install the stud.





7. Position the power steering reservoir bracket and install the bolts.





8. Tighten the EGR valve at the exhaust manifold.





9. Install the nut.





10. Connect the two hoses and the electrical connector to the differential feedback EGR sensor.





11. Connect the vacuum lines and the electrical connector to the EVR.





12. Connect the IAC valve.





13. Connect the TP sensor.





14. Install the balance tube and the bolts and stud.





15. Install the wiring harness shield, the bolts and five clips.





16. Connect the electrical connector to the intake manifold tuning valve.





17. Install the tube assembly and connect the PCV valve tube.





18. Connect the PCV fitting heater coolant hoses.





19. Connect the EVAP return line.





20. Position the cables and bracket and install the bolts.





21. Connect the accelerator cable, speed control cable, and the return spring.





22. Install the engine appearance cover and the three bolts.
23. Refill the engine cooling system.
24. Install the engine air cleaner and outlet tube.