Replacement (Upper)

This article has been updated with bulletin No.: 77-61-18.

UPPER INTAKE MANIFOLD

REMOVAL

1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair
3. Remove the air intake duct.
4. Disconnect the spark plug wires from the right side of the engine. Set the wires aside.
5. Remove the manifold vacuum source.
6. Depressurize the fuel lines. See Powertrain Management.
7. Disconnect the fuel injector wire harness from the fuel injectors.
8. Remove the fuel rail. See Powertrain Management.
9. Remove the EGR heat shield.
10. Remove the cable bracket to the cylinder head mounting bolt.
11. Remove the throttle cable.
12. Remove the throttle body support bracket.

NOTE: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

13. Remove the upper intake manifold bolts.






14. Remove the upper intake manifold.

INSTALLATION

1. Install the upper intake manifold gasket.






2. Install the upper intake manifold.
3. Install the water outlet.

Tightening Sequence:

4. Install the upper intake manifold bolts. Torque in sequence to:
- Torque the vertical bolts in sequence to 15 Nm (11 lb ft).
- Torque the water outlet bolts in sequence to 27 Nm (20 lb ft).
- Torque side bolts in sequence to 30 Nm (22 lb ft).
5. Install the throttle body support bracket.
6. Install the throttle body cable.
7. Install the cable bracket to the cylinder head mounting bolt.
8. Install the EGR heat shield.
9. Install the fuel rail. See Powertrain Management.
10. Connect the fuel injector wire harness to the fuel injectors.
11. Install the manifold vacuum source.
12. Connect the spark plug wire to the right side of the engine.
13. Install the air intake duct.
14. Install the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair
15. Connect the negative battery cable.