Upper Intake Manifold

UPPER INTAKE MANIFOLD

REMOVAL
Non-Turbo





1. Disconnect inlet air temperature sensor and make-up air hose (1) from clean air hose.





2. Remove air cleaner housing (1) 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 (1).





6. idle air control (IAC) motor (1) and throttle position sensor TPS) (3) wiring connectors.





7. Disconnect proportional purge hoses (1).





8. Disconnect brake booster hose.
9. Disconnect PCV hose from intake manifold.





10. Remove rear intake manifold support bracket (1).
11. Remove upper intake manifold fasteners.
12. Remove upper intake manifold.





13. If further service is required, cover the lower intake manifold openings 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 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.





5. Connect PCV hose (2) to intake manifold.





6. Connect manifold absolute pressure (MAP) (1) electrical connector.





7. Connect proportional purge hoses (1).





8. Connect brake booster hose.
9. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.





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 (1) and clean air hose. Tighten clean air hose clamp to 1.7 Nm (15 inch lbs.).
13. Connect make-up (3) air hose and inlet air temperature sensor (2).