Upper Intake Manifold

Removal

NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

1. Remove theAir Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .

2. Disconnect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors.
   • Detach the wiring harness pin-type retainer from the upper intake manifold.

3. Disconnect the EVAP vapor tube from the EVAP canister vent solenoid. For additional information, refer to Section 310-00 .
   • Detach the EVAP vapor tube from the 2 retainers.

4. Release the clamps and disconnect the power brake booster vacuum supply hose and crankcase ventilation hose from the upper intake manifold.

5. Detach the 2 coolant tube retainers from the upper intake manifold.

6. Remove the upper intake manifold support bracket bolt.

7. Remove the 7 bolts and the upper intake manifold.
   • Remove and discard the gasket.
   • Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

Installation

1. Using a new gasket, install the upper intake manifold and the 7 bolts.
   • Tighten in the sequence shown in 2 stages.
     • Stage 1: Tighten to 10 Nm (89 lb-in).
     • Stage 2: Tighten an additional 45 degrees.

2. Install the upper intake manifold support bracket bolt.
   • Tighten to 10 Nm (89 lb-in).

3. Attach the 2 coolant tube retainers to the upper intake manifold.

4. Connect the power brake booster vacuum supply hose and crankcase ventilation hose to the upper intake manifold.

5. Connect the EVAP vapor tube to the EVAP canister vent solenoid. For additional information, refer to Section 310-00 .
   • Attach the EVAP vapor tube to the 2 retainers.

6. Connect the EVAP canister vent solenoid and throttle body electrical connectors.
   • Attach the wiring harness pin-type retainer to the upper intake manifold.

7. Install the ACL outlet pipe. For additional information, refer to Section 303-12 .