Upper

Upper Intake Manifold

Removal

1. Remove cowl top vent panel.
2. Remove air cleaner outlet tube.
3. Disconnect accelerator cable at throttle body. Disconnect speed control actuator,if equipped.
4. Remove retaining bolts from accelerator cable bracket and position cables aside.
5. Disconnect vacuum lines at fuel injection supply manifold and intake manifold.
6. Disconnect necessary electrical connectors.
7. Remove drive belt.
8. Disconnect crankcase ventilation tubes located on upper intake manifold.


Crankcase Ventilation Hose







9. Remove generator brace.
10. Remove throttle body retaining nuts and remove throttle body.
11. Remove Delta PFE assembly and bracket.
12. Remove the EGR valve from the upper intake manifold.
13. Remove the retaining nut and remove wiring retainer bracket located at the LH front of the intake manifold and set aside with ignition wires.
14. Remove bolts securing front and rear intake manifold supports to upper intake manifold.
15. Remove intake manifold upper gasket retaining bolts/studs and intake manifold.
16. Remove intake manifold upper gasket.

Installation

NOTE: Use locating pins to secure position of intake manifold upper gasket between upper and lower intake manifolds.






Item Description
1 Bolt, M8 x 1.25 x 133
2 Stud, M8 x 1.25 x 131.25
3 Upper Intake Manifold
4 Intake Manifold Upper Gasket
5 Lower Intake Manifold


1. Position intake manifold upper gasket and upper intake manifold on top of lower intake manifold
2. Install bolts and studs in original locations. Tighten in numerical sequence using three-step process. Refer to the following illustration for tightening sequence.
a. 10 Nm (8 lb-ft)
b. 20 Nm (15 lb-ft)
c. 32 Nm (24 lb-ft)






3. Install bolts to secure front and rear intake manifold supports to upper intake manifold . Tighten bolts to 20-30 Nm (15-22 lb-ft).
4. Install EGR valve on intake manifold . Tighten retaining nuts to 20-30 Nm (15-22 lb-ft).
5. Install throttle body Cross-tighten retaining nuts to 20-30 Nm (15-22 lb-ft).






6. Install Delta PFE assembly and bracket.
7. Connect rear crankcase ventilation tube at positive crankcase ventilation valve (PCV valve) and upper intake manifold.


Fuel Charging Control






Item Description
1 Bolt (4 Required)
2 Lower Intake Manifold
3 Bolt
4 Fuel Injection Supply Manifold
5 Bolt
6 (Rear) Intake Manifold Support
7 Upper Intake Manifold
8 Cylinder Head
A Tighten to 8-11 Nm (6-8 lb-ft)
B Tighten to 20-30 Nm (15-22 lb-ft)

8. Connect necessary electrical connectors.
9. Connect necessary vacuum hoses.
10. Position accelerator cable bracket. Install and tighten retaining bolts to 20-30 Nm (15-22 lb-ft).
11. Connect speed control actuator,if equipped.

CAUTION: This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant to avoid cooling system damage.

12. Start engine and check for fuel leaks.
13. Adjust speed control.
14. Install engine air cleaner (ACL) and air cleaner outlet tube
15. Install cowl top vent panel.