Upper Intake Manifold

INTAKE MANIFOLD
REMOVAL UPPER INTAKE MANIFOLD

Non-Turbo





1. Disconnect inlet air temperature sensor and make-up air hose from clean air hose (Fig. 133).
2. Remove air cleaner housing and clean air hose assembly
3. Disconnect negative cable from battery.
4. Remove throttle and speed control cables from throttle lever and bracket.








5. Disconnect manifold absolute pressure (MAP) sensor (Fig. 134), idle air control (IAC) motor and throttle position sensor (TPS) wiring connectors (Fig. 135).





6. Disconnect proportional purge hoses (Fig. 136).





7. Disconnect brake booster hose (Fig. 137).
8. Disconnect PCV hose from intake manifold (Fig. 133).





9. Remove rear intake manifold support bracket (Fig. 138).





10. Remove upper intake manifold fasteners (Fig. 150).
11. Remove upper intake manifold.





12. If further service is required, cover the lower intake manifold openings to prevent foreign materials from entering the engine (Fig. 139).

Turbo

NOTE: This engine could be equipped with an aluminum Intake manifold or a plastic intake manifold.

1. Disconnect negative battery cable.





2. Disconnect the inlet air temperature (IAT) sensor connector (Fig. 140).
3. Disconnect the throttle inlet pressure (TIP) hose (Fig. 140).





4. Disconnect charge air cooler hose at throttle body (Fig. 140) and (Fig. 141).
5. Disconnect idle air control (IAC) motor and throttle position sensor connectors.





6. Disconnect the MAP sensor connector (Fig. 142).





7. Remove the throttle control shield (Fig. 143).





8. Remove the throttle cable from the throttle body lever (Fig. 144).
9. If equipped with speed control, remove speed control cable from the throttle lever by sliding clasp out hole used for throttle cable.
10. Remove the 2 screws for the throttle cable bracket.





11. Reposition throttle cable bracket (Fig. 145).
12. Remove intake manifold cover.

NOTE: To remove intake manifold cover, start with clips near throttle body.





13. Disconnect brake booster hose and PCV hose from intake manifold (Fig. 146).
14. Disconnect purge solenoid hose from throttle body (Fig. 146).
15. Remove intake manifold cover.





16. Remove upper intake manifold support bracket (Fig. 147).
17. Remove upper intake manifold fasteners (Fig. 152).
18. Remove upper intake manifold.
19. If further service is required, cover the lower intake manifold openings to prevent foreign materials from entering the engine (Fig. 139).

CLEANING
1. Discard gasket(s).
2. Clean all sealing surfaces.

INSPECTION
1. Inspect manifold for cracks, distortion, or mounting surface warpage. Replace manifold if necessary.
2. Inspect manifold gasket for surface damage or excessive swelling. Replace gaskets as necessary.

INSTALLATION UPPER INTAKE MANIFOLD

Non-Turbo
1. If lower intake manifold was covered during service, remove cover (Fig. 139).
2. Clean all sealing surfaces. Replace seals as necessary.
3. Position new seals on manifold.
4. Position upper intake manifold on lower intake manifold. Tighten upper intake manifold fasteners to 12 Nm (105 inch lbs.) in sequence shown in (Fig. 150).





5. Connect PCV hose to intake manifold (Fig. 151).
6. Connect manifold absolute pressure (MAP) electrical connector (Fig. 134).
7. Connect proportional purge hoses (Fig. 136).
8. Connect brake booster hose (Fig. 137).
9. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors (Fig. 135).
10. Install throttle and speed control cables to bracket. Connect cables to the throttle lever.
11. Connect negative cable to battery.
12. Install air cleaner housing and clean air hose. Tighten clean air hose clamp to 1.7 Nm (15 inch lbs.).
13. Connect make-up air hose and inlet air temperature sensor (Fig. 151).

Turbo
1. If lower intake manifold was covered during service, remove cover (Fig. 139).
2. Clean all sealing surfaces. Replace upper intake manifold gasket.

NOTE: This engine could be equipped with either a plastic intake manifold or an aluminum intake manifold.





3. Position upper intake manifold on lower intake manifold. On engines equipped with an aluminum intake manifold, tighten manifold fasteners to 28 Nm (250 inch lbs.) in sequence shown in (Fig. 152). On engines equipped with a plastic intake manifold, tighten manifold fasteners to 12 Nm (105 inch lbs.) in sequence shown in (Fig. 152).
4. Install upper intake manifold to cylinder head support bracket (Fig. 147). Torque cylinder head fasteners to 28 Nm (250 inch lbs.) and manifold fasteners to 6 Nm (55 inch lbs.).
5. Install the intake manifold cover.
6. Connect purge solenoid hose to throttle body (Fig. 146).
7. Connect brake booster vacuum hose and PCV hose to intake manifold (Fig. 146).
8. Install the 2 screws for the throttle cable bracket and tighten to 12 Nm (105 inch lbs.) on aluminum intake manifolds and 6 Nm (55 inch lbs.) on plastic intake manifolds.
9. If equipped with speed control, install speed control cable to the throttle lever by sliding clasp in the hole used for throttle cable.
10. Install the throttle cable to the throttle body lever (Fig. 144).
11. Install the throttle control shield (Fig. 143).
12. Connect idle air control (IAC) motor and throttle position sensor connectors.
13. Connect the MAP sensor connector (Fig. 142).
14. Connect charge air cooler hose to throttle body (Fig. 140) and (Fig. 141). Tighten hose clamp to 1.7 Nm (15 inch lbs.).
15. Connect negative battery cable.