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Home >> Isuzu >> 1997 >> Hombre S Regular Cab L4-2.2L CPC >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Intake Manifold >> Service and Repair >> Replacement >> Upper
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Upper

REMOVAL
1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly.
3. Discharge the air conditioning system. Refer to Heating and Air Conditioning.
4. Disconnect the A/C line at the evaporator housing. Refer to Heating and Air Conditioning.





5. Remove the throttle cable mounting bracket cover.
6. Remove the throttle body mounting bracket from the throttle body. Leave the throttle cable and the cruise control cable (if equipped) attached to the mounting bracket and lay to the side.
7. Remove the Manifold Absolute Pressure (MAP) sensor.
8. Remove electrical connections for the following components:
^ MAP sensor
^ Idle Air Control (IAC) valve.
^ Throttle Position Sensor (TPS).
9. Disconnect the wiring harness from the intake manifold stud/nuts.
10. Disconnect the vacuum hoses from the throttle body.
11. Disconnect the Positive Crankcase Ventilation (PCV) valve pipe from the valve rocker arm cover.

NOTE: Mark the upper intake manifold bolts and stud/nuts for proper installation.





12. Remove the upper intake manifold bolts and stud/nuts.
13. Remove the upper intake manifold and the gasket.
14. Remove the EGR injector.
15. Inspect all sealing surfaces for warpage or damage. Replace if necessary.





INSTALLATION
1. Install the upper intake manifold gasket.





2. Install the EGR injector.
3. Install the upper intake manifold.





4. Install the upper intake manifold bolts.





^ Tighten the lower intake manifold bolts to 30 Nm (22 ft. lbs.) in sequence.
5. Install the PCV valve pipe.
6. Connect the vacuum hoses to the throttle body.
7. Install the electrical wiring harness to the upper intake manifold stud/nuts.
8. Install the retaining nuts.
9. Install electrical connections for the following components:
^ MAP sensor
^ IAC valve
^ TPS
10. Install the Manifold Absolute Pressure sensor.
11. Install the throttle cable mounting bracket to the throttle body.
^ Tighten the throttle cable mounting bracket bolts to 25 Nm (18 ft. lbs.).
12. Install the A/C line to the evaporator housing. Refer to Heating and Air Conditioning.
13. Charge the A/C system. Refer to Heating and Air Conditioning.
14. Install the air cleaner assembly.
15. Connect the negative battery cable.



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