Upper Intake Manifold
REMOVAL- UPPER INTAKE MANIFOLD1. Disconnect negative battery cable.
2. Remove air cleaner housing and inlet hose.
3. Remove engine cover.
4. Remove throttle and speed control cables from throttle arm and bracket.
5. Remove the two cable bracket retaining bolts and position the cables and bracket assembly out of the way.
6. Remove the oil fill tube to upper intake manifold retaining bolt (Fig. 136).
7. Remove the oil level tube to upper intake manifold retaining bolt (Fig. 136).
8. Disconnect electrical connectors from the following sensors and actuators:
^ Manifold Tuning Valve (MTV)
^ Short Runner Valve
^ Exhaust Gas Recirculation (EGR)
^ Throttle Position Sensor (TPS)
^ Idle Air Control (IAC)
^ Manifold Absolute Pressure (MAP)
9. Remove alternator support bracket (Fig. 137).
10. Disconnect the EGR tube.
11. Disconnect vacuum hoses from the following (Fig. 137):
^ Positive Crankcase Ventilation (PCV) Valve
^ EVAP Purge Solenoid
^ Power Brake Booster
12. Remove the front and rear intake manifold support brackets (Fig. 138). (Fig. 139)
13. Remove the upper intake manifold retaining bolts and manifold. Clean all gasket sealing surfaces.
INSTALLATION - UPPER INTAKE MANIFOLD
1. Clean and inspect gasket sealing surfaces.
2. Position new gasket.
3. Install the throttle body on the upper intake (if required).
4. Install upper intake manifold and hand start all attaching bolts.
5. Tighten bolts gradually starting in the center working outward until a torque of 12 Nm (105 inch lbs.) is obtained.
6. Install the front and rear intake manifold support brackets.
7. Install the oil level indicator and oil fill tube to intake manifold bolts (Fig. 136).
8. Install the EGR tube.
9. Connect vacuum lines to the following (Fig. 137):
^ Positive Crankcase Ventilation (PCV) Valve
^ EVAP Purge Solenoid
^ Power Brake Booster
10. Install alternator support bracket (Fig. 137).
11. Connect electrical connectors to the following (Fig. 138):
^ Manifold Tuning Valve (MTV)
^ Exhaust Gas Recirculation (EGR)
^ Throttle Position Sensor (TPS)
^ Idle Air Control (IAC)
^ Manifold Absolute Pressure (MAP)
12. Install the throttle and speed control cable bracket and retaining bolts.
13. Install throttle and speed control cables to bracket and throttle arm.
14. Install air cleaner housing and inlet hose.
15. Install the engine cover.
16. Connect negative battery cable.