Spark

Upper Intake Manifold Replacement

1. Open the bonnet.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .



3. Disconnect the accelerator cable and reposition the accelerator cable away from intake manifold.



4. Remove the clamps (1, 2).
5. Twist and pull the hoses to remove throttle body assembly.



6. Remove the 4 air cleaner assembly bolts (1).
7. Remove the air cleaner assembly.



8. Disconnect the idle air control valve (IACV) connector (1).
9. Disconnect the throttle position sensor (TPS) connector (2).
10. Disconnect the Manifold absolute pressure (MAP) sensor connector (3).



11. Remove the canister purge solenoid hose (1).



12. Raise the clip (1) upward with suitable tool.



13. Disconnect the coolant bleed hose (1) from the outlet housing.

Note: Plug or cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.

14. Plug or cap the cooling system hoses and inlets.



15. Remove the upper intake manifold to side bracket retaining bolts (1).



16. Disconnect the coolant recovery hose (1) from the outlet housing.

Note: Plug or cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.

17. Plug or cap the cooling system hoses and inlets



18. Disconnect the hose (1) from the upper intake manifold.
19. Disconnect the vacuum hose (2) from the upper intake manifold.



20. Remove the upper intake manifold to front bracket bolts (1).
21. Remove the front bracket (2).



22. Remove the upper intake manifold to lower intake manifold retaining bolts.
23. Remove the upper intake manifold.
24. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement : FX3 → Without FX3 .
25. Remove the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement .

1. Install the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement .
2. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement : FX3 → Without FX3 .
3. Install the upper intake manifold.

Caution: Refer to Fastener Caution in the Preface section.




4. Tighten the upper intake manifold to lower intake manifold retaining bolts to 20 N·m (14.75 lb ft).



5. Install the front bracket (2).
6. Tighten the upper intake manifold to front bracket bolts (1) to 20 N·m (14.75 lb ft).



7. Connect the vacuum hose (2) to the upper intake manifold.
8. Connect the hose (1) to the upper intake manifold.



9. Remove the plug or cap at the coolant hose and outlet housing ends.
10. Connect the coolant recovery hose (1) to the outlet housing.



11. Tighten the upper intake manifold to side bracket retaining bolts (1) to 10 N·m (89 lb in).



12. Connect the coolant bleed hose (1) to the inlet housing.



13. Install the clip (1) while pushing the exhaust gas recirculation (EGR) pipe to the upper intake manifold.



14. Install the canister purge solenoid hose (1).



15. Connect the manifold absolute pressure (MAP) sensor connector (3).
16. Connect the throttle position sensor (TPS) connector (2).
17. Connect the idle air control valve (IACV) connector (1).



18. Install the air cleaner assembly.
19. Tighten the 4 air cleaner assembly bolts (1) to 6 N·m (4 lb in).



20. Twist and pull the hoses to install the throttle body assembly.
21. Tighten the clamps (1, 2).



22. Connect the accelerator cable.
23. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
24. Close the bonnet.