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Notices

Parts/Tools Required

None Listed

Steps

I shouldn't have to say this but there is always someone out there that will do it anyway. Don't do this when the engine is hot. This should only be done on a cold engine.

Removal

1. disconnect the negative battery cable.
2. remove the fuel injector sight shield (engine cover)
3. remove the air cleaner intake duct
4. drain cooling system
5. remove right spark plug wires from the ignition control module and reposition.
6. relieve the fuel pressure.

Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towl before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

7. remove the fuel rail assembly.
8. remove the brake booster hose from the vacuum source manifold.
9. remove the exhaust gas recirculation (EGR) valve wiring harness heat sheild nut, bolt and the EGR heat shield.
10. remove the throttle body support bracket upper bolt.
11. disconnect the electrical connectors from the following:

* EVAP purge solenoid
* throttle position (T/P) sensor
* idle air control (IAC) valve
* manifold absolute pressure (MAP) sensor
* mass air flow (MAF) sensor

12. remove the EVAP purge solenoid vacuum line from the throttle body
13. remove the accelerator and the cruise control cables with the bracket from the throttle body.
14. remove the upper intake manifold bolts and stud.
15. clean the upper intake manifold bolt threads.
16. remove the upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
17. remove the upper-to-lower intake manifold carrier gasket from the upper intake manifold.
18. if the upper intake manifold is being replaced, remove the following:

* throttle body
* manifold absolute pressure (MAP) sensor
* positive crankcase ventilation (PCV) valve
* vacuum source manifold

Installation

1. if the manifold was replaced install the following:

* vacuum source manifold
* positive crankcase ventilation (PCV) valve
* manifold absolute pressure (MAP) sensor
* throttle body

2. install the upper to lower intake manifold carrier gasket to the upper intake manifold
3. carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
4. install the upper intake manifold.
5. apply thread lock compound to the bolt threads before assembly.
6. install the upper intake manifold bolts

Tighten the bolts in sequence to 10 N-m (89 lb in)

7. install the accelerator and the cruise control cables with the bracket to the throttle body
8. install the EVAP purge solenoid vacuum line to the throttle body.
9. connect the electrical connectors to the following:

* mass air flow (MAF) sensor
* manifold absolute pressure (MAP) sensor
* idle air control (IAC) valve
* throttle position (T/P) sensor
* EVAP purge solenoid

10. install the throttle body upper support bracket bolt.

Tighten the bolt to 16 N-m (12 lb in)

11. install the EGR valve wiring harness heat shield nut and bolt.

Tighten the nut and the bolt to 10 N-m (89 lb in)

12. install the brake booster hose to the vacuum source manifold.
13. install the fuel rail assembly.
14. install the right spark plug wires to the ignition control module.
15. install the air cleaner intake duct.
16. install the fuel injector sight shield.
17. fill the cooling system.
18. connect the negative battery cable.
19. inspect for fluid or vacuum leaks.

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