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Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure


1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .

2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (LAU) Air Cleaner Outlet Duct Replacement (LF1) .

3. Disconnect evaporative pipes as needed.

4. Remove the engine coolant air pipe. Refer to Engine Coolant Air Bleed Pipe Replacement (LAU) Engine Coolant Air Bleed Pipe Replacement (LF1) .

5. Remove the charge air cooler outlet duct. Refer to Charge Air Cooler Outlet Duct Replacement .

6. Remove the secondary air injection pump pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

7. Remove the fuel injector wiring harness plug from fuel injector wiring harness bracket.


8. Remove the power brake booster vacuum pipe connector (4) from the power brake booster vacuum pipe.


9. Remove the 4 long intake manifold bolts (1).

10. Remove the short intake manifold bolts (2).

11. Remove the upper intake manifold (3).

12. Disconnect the electrical connectors.

13. Remove the upper intake manifold gasket left side (1).


14. Remove the upper intake manifold gasket right side (2).

15. Remove the 2 upper-to-lower intake manifold alignment pins (1).



Installation Procedure


1. Install the 2 upper-to-lower intake manifold alignment pins (1).


2. Install the NEW upper intake manifold gasket bank 1 (2).


3. Install the NEW upper intake manifold gasket bank 2 (1).

4. Install the upper intake manifold (3).


5. Refer to Fastener Caution

Install the two short intake manifold bolts (2) and tighten to 23 Nm (17 lb ft) .

6. Install the four long intake manifold bolts (1) and tighten to 23 Nm (17 lb ft) .

7. Install the power brake booster vacuum pipe connector (4) to the power brake booster vacuum pipe.

8. Install the electrical connector.

9. Install the fuel injector wiring harness plug to fuel injector wiring harness bracket.


10. Install the secondary air injection pump pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

11. Install the charge air cooler outlet duct. Refer to Charge Air Cooler Outlet Duct Replacement .

12. Install the engine coolant air pipe. Refer to Engine Coolant Air Bleed Pipe Replacement (LAU) Engine Coolant Air Bleed Pipe Replacement (LF1) .

13. Connect evaporative pipes as needed.

14. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (LAU) Air Cleaner Outlet Duct Replacement (LF1) .

15. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement