Upper Intake Manifold

UPPER INTAKE MANIFOLD

REMOVAL





1. Disconnect negative battery cable.
2. Disconnect the IAT sensor electrical connector.
3. Remove air inlet hose from the throttle body.





4. Disconnect the MAP sensor electrical connector.





5. Separate the engine electrical harness connectors from the intake manifold.

NOTE: Replace the EGR tube gasket and silicone rubber seals any time the EGR tube is removed from the intake manifold.

6. Remove the upper EGR tube from the intake manifold, and the upper EGR tube from the EGR valve.

7. Disconnect the EGR tube, PCV, Purge and power brake booster vacuum hoses from the upper intake manifold.
8. Disconnect the electronic throttle control electrical connector.
9. Remove the throttle bracket (4) fasteners from the throttle body and cylinder head.





10. Disconnect electrical connectors from the Manifold Tuning Valve (MTV) and Short Runner Valve.





11. Remove the right intake manifold support brackets.
12. Remove the upper intake manifold retaining bolts, insulation foam pad and manifold. Clean all gasket sealing surfaces.

INSTALLATION
1. Clean and inspect gasket sealing surfaces.
2. Position new gasket.





3. Install the upper intake manifold insulator foam.
4. Install the upper intake manifold. Tighten bolts to 12 Nm (105 inch lbs.) starting in the center working outward in a cross sequence pattern.
5. Install the right manifold support brackets. Tighten fasteners to 12 Nm (105 inch lbs.).





6. Install the throttle bracket. Tighten fasteners to 12 Nm (105 inch lbs.) at the throttle body and 28 Nm (259 inch lbs.) at the cylinder head.





7. Connect the manifold tuning valve and short runner valve electrical connectors.





8. Connect the electronic throttle control harness connector.
9. Connect the engine electrical connectors to the intake manifold.

NOTE: Replace the EGR tube gasket and silicone rubber seals any time the EGR tube is removed from the intake manifold.

10. Verify the upper EGR tube seal (1) is positioned correctly on the EGR tube assembly.

11. Install the EGR tube (3), and verify the seal is correctly positioned in the intake manifold.

12. Connect the EGR tube, PCV, Purge and power brake booster vacuum hoses to the intake manifold.





13. Connect the MAP sensor harness connector.





14. Install the inlet hose and connect the IAT sensor harness connector.
15. Connect negative battery cable.