Replacement (Upper)
REMOVAL PROCEDUREIMPORTANT: The fuel injector wiring harness connectors must be connected to their respective fuel injectors. Failure to connect the fuel injector connectors to their respective fuel injectors may result in excessive exhaust emissions and poor engine performance.
1. Disconnect the battery ground (negative) cable.
2. Remove the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair
3. Drain the engine coolant from the cooling system.
4. Remove the throttle body air inlet duct.
5. Remove the accelerator control and cruise control cables with bracket from the throttle body.
6. Disconnect the wiring harness connectors from the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve.
7. Disconnect the engine left side spark plug wires.
8. Disconnect the engine left side spark plug wire harness attachment clip.
9. Disconnect the throttle body heater hoses from the throttle body.
10. Disconnect the vacuum hoses from the evaporative emissions canister purge solenoid valve.
11. Remove the evaporative emissions canister purge solenoid valve.
12. Remove the ignition coil bracket with the coils.
13. Disconnect the wiring harness from the Manifold Air Pressure (MAP) sensor.
14. Disconnect the vacuum hose from the Manifold Air Pressure (MAP) sensor and the upper intake manifold.
15. Disconnect and remove the emission control vacuum harness.
16. Disconnect the vacuum brake booster hose from the upper intake manifold.
17. Disconnect the vacuum hose/pipe connections from the following:
^ The automatic transaxle vacuum modulator
^ The HVAC vacuum source fitting
^ The fuel pressure regulator
18. Remove the generator front brace.
19. Remove the generator rear brace.
20. Remove the Exhaust Gas Recirculation (EGR) valve.
21. Remove the Manifold Air Pressure (MAP) sensor and the bracket.
22. Remove the upper intake manifold studs and bolts.
23. Remove the upper intake manifold.
24. If you are replacing the intake manifold, remove the throttle body.
25. Remove the upper intake manifold gasket.
26. Clean and inspect the upper intake manifold.
INSTALLATION PROCEDURE
1. If removed, install the throttle body.
2. Install the upper intake manifold gasket.
3. Install the upper intake manifold.
4. Install the Manifold Air Pressure (MAP) sensor and the bracket.
5. Install the upper intake manifold studs.
6. Install the upper intake manifold bolts.
Tighten the upper intake manifold studs and bolts to 25 Nm (18 ft. lbs.).
7. Install the Exhaust Gas Recirculation (EGR) valve.
8. Install the generator front brace.
9. Install the generator rear brace.
10. Connect the vacuum hose/pipe connections to the following:
^ The automatic transaxle vacuum modulator
^ The HVAC vacuum source fitting
^ The fuel pressure regulator
11. Connect the vacuum brake booster hose to the upper intake manifold.
12. Install the Manifold Air Pressure (MAP) sensor and the bracket.
13. Install and connect the emission control vacuum harness.
14. Connect the vacuum hose to the Manifold Air Pressure (MAP) sensor and the upper intake manifold.
15. Connect the wiring harness to the Manifold Air Pressure (MAP) sensor.
16. Install the ignition coil bracket with the coils.
17. Install the evaporative emissions canister purge solenoid valve.
18. Connect the vacuum hoses to the evaporative emissions canister purge solenoid valve.
19. Connect the throttle body heater hoses from the throttle body.
20. Connect the engine left side spark plug wire harness attachment clip.
21. Connect the engine left side spark plug wires.
22. Connect the wiring harness connectors to the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve.
23. Install the accelerator control and cruise control cables with bracket to the throttle body.
24. Install the throttle body air inlet duct.
25. Fill the cooling system with engine coolant.
26. Install the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair
27. Connect the battery ground (negative) cable.