Upper Manifold Assembly

Upper Manifold Removal:

REMOVAL PROCEDURE
1. Disconnect the negative battery cable.
2. Remove the air intake duct.
3. Remove the accelerator cable splash shield from accelerator cable bracket.
4. Disconnect the accelerator, the cruise, and the transmission control cables.
. Remove the vacuum hose harness from top of the air inlet.
6. Disconnect the crankcase ventilation valve and the power brake vacuum hoses from the vacuum tubes at the upper manifold (position vacuum hoses out of the way).
7. Remove the electrical connectors at MAP sensor, TP sensor, and IAC valve.
8. Remove the bolts/nuts attaching accelerator cable bracket (position bracket and cables out of the way).
9. Remove the MAP sensor.
10. Remove the bolts/studs (1) attaching upper manifold to the lower manifold (position fuel injector wiring harness out of the way).
11. Remove the upper manifold assembly (2) and gasket (3) (discard gasket).

CAUTION: In order to prevent damage to the sealing surfaces, carefully use sharp tools in cleaning the old gasket from the aluminum surfaces.

12. Clean the gasket mating sufaces.
13. Inspect the replacement upper manifold for items that are to be transferred to the new manifold.
14. Disassemble the upper manifold following the component repair procedures.
15. Assemble the replacement upper manifold with the transferred parts following the component repair procedures.

INSTALLATION PROCEDURE
The EVAP canister may have released carbon particles which may have caused this parts failure. Check the EVAP canister for carbon before returning to the vehicle to service.

1. Install the new upper manifold gasket (3).
2. stall the upper manifold assembly (2) (reposition the injector wiring harness).
3. stall the upper manifold attaching bolts/studs (1).
4. Tighten the upper manifold bolts/studs to the tightening sequence shown.

Tighten
Bolts/studs to 30 Nm (22 lb ft). Refer to tightening sequence.

. Install the MAP sensor.
6. Install the accelerator cable bracket with attaching bolt/nuts.

Tighten
Bracket nut to 30 NM (22 lb ft).
Bolts to 25 Nm (18 lb ft).

7. Install the accelerator, cruise, and transmission control cables.
8. Install the splash shield to accelerator bracket.

Tighten
Shield screws to 1.9 Nm (17 lb in).

9. Install the electrical connectors to the MAP sensor, the TP sensor, the IAC valve, and the EGR vacuum solenoid.
10. Install the vacuum hose harness to the top of the air inlet.
11. Connect the crankcase ventilation valve and the power brake vacuum hoses to the vacuum tubes at the upper manifold.
12. Install the air intake duct.
13. Connect the negative battery cable.