Upper Intake Manifold

Upper Intake Manifold

Upper Intake Manifold:

Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the air cleaner outlet pipe.
4. Drain the cooling system.
5. Remove the 2 bolts and the accelerator cable snow shield.
6. Disconnect the speed control and accelerator cables from the throttle body.
7. Remove the 3 accelerator/speed control cable bracket bolts and position the cables and brackets aside.
8. Disconnect the exhaust gas recirculation (EGR) tube fitting from the EGR valve.
9. Disconnect the throttle position (TP) sensor electrical connector and detach the wiring retainer.
10. Detach the transaxle vent tube from the throttle body stud bolt.
11. Disconnect the vacuum harness tube fittings from the EGR valve and the EGR vacuum regulator.
12. Disconnect the idle air control (IAC) valve electrical connector.
13. Disconnect the EGR vacuum regulator electrical connector.
14. Remove the nut from the EGR vacuum regulator stud bolt and detach the wiring retainer.
15. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold.
16. Detach the main engine wiring harness electrical connectors from the upper intake manifold.
17. Disconnect the 2 throttle body coolant hoses.
18. Remove the 8 bolts and the upper intake manifold.

Installation





1. NOTE: Clean and inspect all sealing surfaces. Inspect and install new gaskets as necessary.

Position the upper intake manifold and install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).
2. Connect the 2 throttle body coolant hoses.
3. Attach the main engine wiring harness electrical connectors to the upper intake manifold.
4. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold.
5. Attach the wiring retainer to the EGR vacuum regulator stud bolt and install the nut.
^ Tighten to 6 Nm (53 inch lbs.).
6. Connect the EGR vacuum regulator electrical connector.
7. Connect the IAC valve electrical connector.
8. Connect the vacuum harness tube fittings to the EGR valve and the EGR vacuum regulator.
9. Attach the transaxle vent tube to the throttle body stud bolt.
10. Connect the TP sensor electrical connector and attach the wiring retainer.
11. Connect the EGR tube fitting to the EGR valve.
^ Tighten to 40 Nm (30 ft. lbs.).
12. Position the accelerator/speed control cables and brackets and install the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
13. Attach the speed control and accelerator cables to the throttle body.
14. Install the accelerator cable snow shield and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
15. Install the air cleaner outlet pipe.
16. Connect the battery ground cable.
17. Fill and bleed the cooling system.