Upper Intake Manifold

UPPER INTAKE MANIFOLD

REMOVAL





1. Disconnect inlet air temperature sensor and make-up air hose from clean air hose (Fig. 117).
2. Remove air cleaner housing and clean air hose assembly.
3. Disconnect negative cable from battery.





4. Remove engine cover by pulling upward to release from ball stud retainers (Fig. 118).
5. Remove throttle and speed control cables from throttle lever and bracket.








6. Disconnect Manifold Absolute Pressure (MAP) sensor (Fig. 119), Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors (Fig. 120).





7. Disconnect proportional purge hoses (Fig. 121).





8. Disconnect brake booster hose (Fig. 122).





9. Disconnect PCV hose from intake manifold (Fig. 123).
10. Remove throttle body support bracket bolt at the throttle body (Fig. 123).





11. Remove EGR tube bolts at the upper intake manifold (Fig. 124).





12. Remove upper intake manifold fasteners (Fig. 128).
13. Remove upper intake manifold.





14. If further service is required, cover the lower intake manifold openings to prevent foreign materials from entering the engine (Fig. 125).

INSTALLATION - UPPER INTAKE MANIFOLD
1. Clean all sealing surfaces. Replace seals as necessary.
2. Position new seals on manifold, if replaced.





3. Inspect EGR tube seal (Fig. 127). Replace as necessary.
4. First, carefully position the upper intake manifold onto the EGR tube (Fig. 127). Then position upper intake manifold on lower intake manifold.
Tighten upper intake manifold fasteners to 12 Nm (105 inch lbs.) in sequence shown in (Fig. 128).
5. Install throttle body support bracket bolt at throttle body (Fig. 123). Tighten bolt to 28 Nm (20 ft. lbs.).
6. Position EGR tube retainer plate and install bolts (Fig. 124). Tighten smaller bolt to 11 Nm (95 inch lbs.) and larger bolt to 28 Nm (20 ft. lbs.).
7. Connect PCV hose to intake manifold (Fig. 123).
8. Connect Manifold Absolute Pressure (MAP) electrical connector (Fig. 119).
9. Connect proportional purge hoses (Fig. 121).
10. Connect brake booster hose (Fig. 122).
11. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors (Fig. 120).
12. Install throttle and speed control cables to bracket. Connect cables to the throttle lever.
13. Connect negative cable to battery.
14. Install air cleaner housing and clean air hose.
Tighten clean air hose clamp to 1.7 Nm (15 inch lbs.).
15. Connect make-up air hose and inlet air temperature sensor (Fig. 117).
16. Install engine cover by positioning on ball studs and gently press down until seated (Fig. 118).