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Home >> Isuzu >> 1996 >> Hombre L4-2.2L CPC >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Intake Manifold >> Service and Repair >> Upper Manifold Assembly

Upper Manifold Assembly

Identification Label Location:




A label containing the last four digits of the upper manifold assembly identification number appears above the power brake fitting assembly as shown. The bar code (read by an optical scanner) also contains the component number for manifolds, and the four digits of the identifying number. Refer to this number if servicing or part replacement is required.
Refer to the disassembled view for identification of parts during repair procedures.

Figure 4C-8 Upper And Lower Intake Components:




Legend:
1. Manifold Assembly - Upper
2. Stud - Upper Inlet Manifold
3. Harness Assembly - EGR Valve and Fuel Pressure Regulator Vacuum
4. Seal - MAP sensor
5. Sensor- Manifold Absolute Pressure (MAP)
6. Bolt - MAP Sensor Attaching
7. Fitting and Washer Assembly - EGR Transfer Tube
8. Valve Assembly - Idle Air Control (IAC)
9. Screw - AC Valve Attaching
10. 0-Ring - IAC Valve
11. Tube Assembly - EGR transport
12. Bolt - Upper Inlet Manifold
13. Gasket - Upper Inlet Manifold
14. Fitting - Power Brake
15. 0-Ring - Fuel Inject or Upper
16. Injector Assembly - (Bottom Feed) SFI Fuel injectors
17. 0-Ring - Fuel Injector Lower
18. Screw - Fuel Pressure Connection Fitting
19. Bracket - Fuel Pressure Connection Fitting
20. Fitting - Fuel Feed
21. 0-Ring - Fuel Feed Pipe Fitting
22. 0-Ring - Fuel Feed Pipe Fitting
23. Pipe Assembly - Fuel Feed
24. Manifold Assembly - Lower
25. Retainer - Injectors
26. Screw - Injectors Retainer Attaching
27. Screw - TP Sensor Attaching
28. Sensor - Throttle Position (TP)
29. Pipe Assembly - Fuel Return
30. 0-Ring - Fuel Return Pipe Fitting
31. Screen - Filter (if so equipped)
32. 0-Ring - Fuel Pressure Regulator
33. Screw - Fuel Pressure Regulator Attaching
34. Regulator Assembly - Fuel Pressure

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Air intake duct.
3. Accelerator cable splash shield from accelerator cable bracket.
4. Accelerator, cruise, and transmission control cables.
5. Vacuum hose harness from top of air inlet.
6. Disconnect crankcase ventilation valve and power brake vacuum hoses from vacuum tubes at upper manifold.
- Position vacuum hoses out of the way.
7. Electrical connectors at MAP sensor, TP sensor, and IAC valve.
8. Bolts/nuts attaching throttle cable bracket.
- Position bracket and cables out of the way.
9. Bolts/studs attaching upper manifold to lower manifold.
- Position EGR and injector wiring harness out of the way.
10. Upper manifold assembly and gasket.
- Discard gasket.
11. Clean Gasket surfaces.

NOTE: Use care in cleaning old gasket material from machined aluminum surfaces as sharp tools may damage sealing surfaces.

CLEANING INSTRUCTIONS
The upper manifold contains integral sealed throttle shaft bearings and parts that should not be cleaned or soaked in a cold immersion cleaner. Use carburetor choke cleaner and a shop towel or a nonmetallic parts cleaning brush to remove any carbon deposits.


NOTE: The upper manifold assembly contains the TP sensor, AC valve, and sealed throttle shaft bearings which should not be subjected to a strong solvent or cleaner bath. A chemical reaction will cause the parts containing rubber to swell, harden or distort, and the cleaner will also wash away the sealed bearing grease, or weaken its lubrication properties.

INSPECT
Replacement upper manifold for items that are to be transferred from unit removed from engine.

DISASSEMBLE
- Upper manifold following component repair procedures.
- Power brake vacuum fitting.

ASSEMBLE
- Replacement upper manifold with transferred parts following component repair procedures.
- Power brake vacuum fitting coated with appropriate thread-locking material.

Tighten Power brake vacuum fitting to 13.0 Nm (115 in. lbs.).

INSTALL OR CONNECT
Position EGR valve injector so that the port faces directly toward the throttle bore.
1. New upper manifold gasket.
2. Upper manifold assembly.
- Reposition EGR and injector wiring harness.
3. Upper manifold attaching bolts/studs.

Tighten Upper manifold bolts/studs to 30.0 Nm (22 ft. lbs.).

4. Accelerator cable bracket with attaching bolt/nuts.

Tighten
- Accelerator cable bracket nut to 30 Nm (22 ft. lbs.).
- Accelerator cable bracket bolts to 25 Nm (18 ft. lbs.).

5. Accelerator cables.
6. Splash shield to accelerator bracket.
7. Electrical connectors to MAP sensor, TP sensor, IAC valve, and EGR valve.
8. Vacuum hose harness to top of air inlet.
9. Connect crankcase ventilation valve and power brake vacuum hoses to vacuum tubes at upper manifold.
10. Negative battery cable.
11. Air intake duct.

INSPECT
Turn ignition switch to the "ON" position for two seconds, then turn to the "OFF" position for ten seconds. Again turn to the "ON" position, and check for fuel leaks.

IMPORTANT: The hardware used to attach the upper manifold Throttle Position (TP) sensor, Idle Air Control (IAC) valve, MAP sensor, power brake fitting, and the lower manifold pressure regulator and injector bracket attaching hardware are coated with thread-locking adhesive. If any these parts are removed for service, inspect the attaching screw threads. There should be enough thread-locking material (adhesive or compound) on the threads to ensure proper relocking. If not, clean the threads and apply a thread locking adhesive to the threads before reassembly. Replacement screws are included in the service screw assortment package. New attaching hardware is included in the service packages.

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