Upper Intake Manifold

Upper Intake Manifold

Removing

- Disconnect the negative battery cable.

- Remove the engine cover (1).






- Drain the engine cooling system. Refer to => [ Cooling System Draining and Filling ] Cooling System Draining and Filling.

- Disengage the upper radiator hose retainer (1) from the upper intake manifold.






- Remove the engine cooling fan. Refer to => [ Engine Cooling Fan ] Description and Operation.

- Remove the intake resonator. Refer to => [ Air Cleaner Resonator ] Service and Repair.

- Disconnect the electrical connectors from the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (7).






- Disengage the ETC harness from the clip (8) on the throttle body. Disengage the wire harness retainers (4 and 5) from the upper intake manifold near the MAP sensor and reposition the wire harness.

- Disconnect the following hoses from the upper intake manifold:

• Positive Crankcase Ventilation (PCV) (3)

• Vapor purge (6)

• Brake booster (2)

- Disengage the wire harness retainer (4) from the upper intake manifold support bracket (5).






- Disengage the wire harness retainer (3) from the stud bolt (2).

- Remove two nuts (1), loosen the stud bolt (2) and reposition the upper intake manifold support bracket (5).

- Remove the nut (2) from the support bracket of the heater core return tube (1).






- Remove two nuts (1), loosen two stud bolts (3) and reposition the two upper intake manifold support brackets (2).






• The upper intake manifold attaching bolts are captured in the upper intake manifold. Once loosened, the bolts will have to be lifted out of the lower intake manifold and held while removing the upper intake manifold.

- Remove seven manifold attaching bolts (1) and remove the upper intake manifold (2).






- Remove and discard the six upper to lower intake manifold seals (1).






- Cover the open intake ports to prevent debris from entering the engine.

- If required, remove the insulator (2) from the LH cylinder head cover.

Installing

- Clean and inspect the sealing surfaces. Install new upper to lower intake manifold seals (1).






• Make sure the fuel injectors and wiring harnesses are in the correct position so that they don't interfere with the upper intake manifold installation.

- If removed, install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.






- Lift and hold the seven upper intake attaching bolts (1) clear of the mating surface. Back the bolts out slightly or if required, use an elastic band to hold the bolts clear of the mating surface.

- Position the upper intake manifold (1) onto the lower intake manifold so that the two locating posts (2) on the upper intake manifold align with corresponding holes (3) in the lower intake manifold.






- Install the seven upper intake manifold attaching bolts. Tighten the bolts in the sequence shown to 9 Nm (80 in. lbs.).

- Install two nuts (1) to the upper intake manifold support bracket (5). Tighten the nuts (1) to 10 Nm (89 in. lbs.) and tighten the stud bolt (2) to 20 Nm (177 in. lbs.)






- Engage the wire harness retainer (3) to the stud bolt (2).

- Engage the wire harness retainer (4) to the upper intake manifold support bracket (5).

- Install two upper intake manifold support brackets (2) with two stud bolts (3) and two nuts (1). Tighten the stud bolts (3) to 20 Nm (177 in. lbs.) and tighten the nuts (1) to 10 Nm (89 in. lbs.).






- Install the nut (2) to the support bracket of the heater core return tube (1) and tighten to 12 Nm (106 in. lbs.).






- Connect the following hoses to the upper intake manifold:






• Positive Crankcase Ventilation (PCV) (3)

• Vapor purge (6)

• Brake booster (2)

- Connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (7).

- Secure the ETC harness to the clip (7) on the throttle body and engage the wire harness retainers (4 and 5) to the upper intake manifold near the MAP sensor.

- Install the engine cooling fan and shroud assembly. Refer to => [ Engine Cooling Fan ] Description and Operation.

- Engage the upper radiator hose retainer (1) to the upper intake manifold.






- Install the intake resonator. Refer to => [ Air Cleaner Resonator ] Service and Repair.

- Connect the negative battery cable.

- Fill the cooling system. Refer to => [ Cooling System Draining and Filling ] Cooling System Draining and Filling.

- Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

- Install the engine cover (1).