Intake Manifold Replacement Upper

1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly.
3. Discharge the air conditioning system. Refer to Heating, Ventilation and Air Conditioning.
4. Disconnect the A/C line at the evaporator housing. Refer to Heating Ventilation and Air Conditioning.
5. Remove the throttle cable mounting bracket cover.



6. Remove the throttle body mounting bracket from the throttle body.

Leave the throttle cable and the cruise control cable (if equipped) attached to the mounting bracket and lay to the side.

7. Remove the Manifold Absolute Pressure (MAP) sensor.
8. Remove electrical connections for the following components:

•	Manifold Absolute Pressure (MAP) sensor

•	Idle Air Control (IAC) valve

•	Throttle Position Sensor (TPS)

9. Disconnect the wiring harness from the intake manifold stud/nuts.
10. Disconnect the vacuum hoses from the throttle body.
11. Disconnect the Positive Crankcase Ventilation (PCV) valve pipe from the valve rocker arm cover.

Important: Mark the upper intake manifold bolts and stud/nuts for proper reinstallation.




12. Remove the upper intake manifold bolts and stud/nuts.
13. Remove the upper intake manifold and the gasket.
14. Remove the EGR injector.
15. Inspect all sealing surfaces for warpage or damage. Replace if necessary.

1. Install the upper intake manifold gasket.



2. Install the EGR injector.



3. Install the upper intake manifold.



4. Install the upper intake manifold bolts.

Tighten
Tighten the lower intake manifold bolts to 30 N·m (22 lb ft) in sequence.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the Positive Crankcase Ventilation (PCV) valve pipe.
6. Connect the vacuum hoses to the throttle body.
7. Install the electrical wiring harness to the upper intake manifold stud/nuts.
8. Install the retaining nuts.
9. Install electrical connections for the following components:

•	Manifold Absolute Pressure (MAP) sensor

•	Idle Air Control (IAC) valve

•	Throttle Position Sensor (TPS)

10. Install the Manifold Absolute Pressure sensor.



11. Install the throttle cable mounting bracket to the throttle body.

Tighten
Tighten the throttle cable mounting bracket bolts to 25 N·m (18 lb ft).

12. Install the A/C line to the evaporator housing. Refer to Heating Ventilation and Air Conditioning.
13. Charge the A/C system. Refer to Heating Ventilation and Air Conditioning.
14. Install the air cleaner assembly.
15. Connect the negative battery cable. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

Intake Manifold Replacement Lower

1. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
2. Drain the cooling system. Refer to Cooling and Radiator.
3. Remove the upper radiator hose from the thermostat housing and the radiator. Refer to Cooling and Radiator.
4. Remove the heater hose from the thermostat housing and the heater core. Refer to Heating, Ventilation and Air Conditioning.



5. Remove the vacuum hose from the fuel pressure regulator.
6. Remove the fuel feed pipe from the fuel pressure regulator.



7. Remove the fuel pressure regulator.
8. Remove the fuel return pipe from the fuel rail.
9. Remove the electrical connectors from the fuel injectors.
10. Remove the spark plug wires from the spark plugs.
11. Remove the brace from the generator to the intake manifold stud.
12. Remove the lower intake manifold bolts and nuts.



13. Remove the lower intake manifold.
14. Inspect all sealing surfaces for warpage or damage. Replace if necessary.

1. Install the lower intake manifold gasket.



2. Install the lower intake manifold.



3. Install the lower intake manifold nuts.

Tighten
Tighten the lower intake manifold nuts to 33 N·m (24 lb ft) in sequence.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the brace from the generator to the lower intake manifold.
5. Install the spark plug wires to the spark plugs.
6. Install the electrical connectors to the fuel injectors.
7. Install the fuel pipe to the fuel rail.



8. Install the fuel pressure regulator to the lower intake manifold.
9. Install the fuel pipe to the fuel pressure regulator.



10. Install the vacuum hose to the fuel pressure regulator.
11. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement .
12. Install the heater hose from the heater core to the upper thermostat housing. Refer to Heating, Ventilation and Air Conditioning.
13. Install the upper radiator hose to the upper thermostat housing to the radiator. Refer to Cooling and Radiator.
14. Fill the cooling system. Refer to Cooling and Radiator.
15. Install the air cleaner assembly.
16. Connect the negative battery cable. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    .