Upper Intake Manifold
Upper Intake ManifoldRemoval
1. Remove the cowl grille.
2. Disconnect the battery ground cable.
3. Remove the bolts and five clips and the wiring harness shield.
4. Remove the engine appearance cover.
5. Partially drain the engine cooling system.
6. Remove the air cleaner outlet tube and the air cleaner assembly.
7. Disconnect the accelerator cable, speed control cable, and the return spring.
8. Remove the bolts and position the cables and bracket out of the way.
9. Disconnect the Evaporative Emission (EVAP) return hose.
10. Disconnect and remove the Positive Crankcase Ventilation (PCV) tube.
11. Disconnect the coolant hoses.
12. Remove the bolts, studs and the balance tube.
13. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Remove and discard the gaskets and clean the sealing surfaces.
14. Disconnect the Throttle Position (TP) sensor electrical connector.
15. Disconnect the Idle Air Control (IAC) valve electrical connector.
16. Disconnect the vacuum hoses and the electrical connector from the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid.
17. Disconnect the two hoses and the electrical connector from the differential pressure feedback EGR system.
18. Remove the nut.
19. 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.
20. Remove the stud and position the oil fill tube aside.
21. Disconnect the brake booster vacuum hose.
22. Disconnect the vacuum hose.
23. Disconnect the vacuum hose from the EGR valve.
24. Disconnect the vacuum hose.
25. Disconnect the vacuum hose at the right rear of the intake manifold.
26. Remove the bolts from the EGR adapter.
^ Discard the casket.
27. Remove the bolts and the upper intake manifold.
^ Discard the upper intake retaining bolts.
28. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Remove and inspect the intake gasket. Install a new gasket if necessary.
^ Clean and inspect the sealing surfaces.
Installation
1. Install the upper intake manifold gasket.
2. NOTE: Install new bolts.
Position the upper intake manifold and loosely install the new bolts.
3. Tighten the bolts in the sequence shown in two stages.
^ Tighten to 10 Nm (89 inch lbs.).
^ Tighten an additional 90°.
4. Install the EGR adapter using a new gasket.
5. Connect the vacuum hose to the EGR valve.
6. Connect the vacuum hose at the right rear of the intake manifold.
7. Connect the vacuum hose.
8. Connect the brake booster vacuum hose.
9. Position the oil fill tube and install the stud.
10. Position the power steering reservoir bracket and install the bolts.
11. Install the nut.
12. Connect the two vacuum hoses and the electrical connector to the differential pressure feedback EGR system.
13. Connect the vacuum hoses and the electrical connector to the EGR vacuum regulator solenoid.
14. Connect the IAC valve electrical connector.
15. Connect the TP sensor electrical connector.
16. Install the balance tube gaskets.
17. Install the balance tube, the bolts and the stud.
18. Connect the PCV heater coolant hoses.
19. Install the tube assembly and connect the PCV valve tube.
20. Connect the EVAP return hose.
21. Position the cables and bracket, and install the bolts.
22. Connect the accelerator cable, speed control cable and the return spring.
23. Install the engine air cleaner and outlet tube.
24. Install the engine appearance cover.
25. Install the wiring harness shield, the bolts and five clips.
26. Install the cowl grille.
27. Connect the battery ground cable.
28. Fill the engine cooling system.