Upper Intake Manifold

UPPER INTAKE MANIFOLD

REMOVAL
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 (2) connector.
3. Disconnect the throttle inlet pressure (TIP) hose (3).





4. Disconnect charge air cooler hose at throttle body (1).
5. Disconnect idle air control (IAC) motor and throttle position sensor connectors.





6. Disconnect the MAP sensor connector (1).





7. Remove the throttle control shield.





8. Remove the throttle cable from the throttle body lever.
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.
12. Remove intake manifold cover.

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





13. Disconnect brake booster hose (3) and PCV hose (3) from intake manifold.
14. Disconnect purge solenoid hose (1) from throttle body





15. Remove upper intake manifold support bracket (2).
16. Remove upper intake manifold fasteners (1).
17. Remove upper intake manifold.





18. If further service is required, cover the lower intake manifold openings (1) to prevent foreign materials from entering the engine.

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





1. If lower intake manifold was covered during service, remove cover (1).
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. On engines equipped with a plastic intake manifold, tighten manifold fasteners to 12 Nm (105 inch lbs.) in sequence shown.





4. Install upper intake manifold to cylinder head support bracket (1). 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 (1).





6. Connect purge solenoid hose to throttle body (1).





7. Connect brake booster vacuum hose and PCV hose to intake manifold.
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. Install the throttle control shield.
10. Connect idle air control (IAC) motor and throttle position sensor connectors.





11. Connect the MAP sensor (1) connector.





12. Connect charge air cooler hose to throttle body (1). Tighten hose clamp to 1.7 Nm (15 inch lbs.).
13. Connect negative battery cable.