Upper Manifold Replacement
REMOVAL1. Disconnect negative cable from battery remote jumper terminal.
2. Remove air inlet resonator and inlet tube.
3. Remove throttle cable and speed control cable from throttle arm and bracket.
4. Remove throttle cable bracket.
5. Disconnect electrical connectors from the following components:
^ Manifold Absolute Pressure (MAP) Sensor
^ Intake Air Temperature (IAT) Sensor
^ Throttle Position Sensor (TPS) Sensor
^ Idle Air Control (IAC) Motor
6. Disconnect Vapor Purge hose, Brake Booster hose, Speed Control Servo, Positive Crankcase Ventilation (PCV) hose.
7. Remove EGR tube.
8. Loosen upper fastener at throttle body support bracket.
Fig. 35
9. Remove upper fasteners from support brackets at right and left side of upper manifold (Fig. 35).
10. Remove engine name cover from manifold by applying upward pressure to release retaining clip.
11. Remove manifold attaching bolts.
12. Remove upper manifold.
INSTALLATION
1. Clean and inspect sealing surfaces. Gaskets can be reused, if free of cuts or tears.
NOTE: Make sure fuel injectors and wiring harnesses are in correct position to not interfere with upper manifold installation
2. Position upper manifold onto lower manifold.
Fig. 36
3. Install manifold attaching bolts and tighten in sequence shown in (Fig. 36) to 12 Nm (105 inch lbs.).
4. Install fasteners to right and left side support brackets to manifold. Tighten lower fastener to 6 Nm (50 inch lbs.). Then tighten upper fastener to 12 Nm (105 inch lbs.).
5. Install engine name cover to manifold.
6. Tighten upper fastener at throttle body support bracket.
7. Install EGR tube to manifold.
8. Connect speed control servo hose, PCV hose, and vapor purge hoses.
9. Connect electrical connectors to the following components:
^ Manifold Absolute Pressure (MAP) Sensor
^ Intake Air Temperature (IAT) Sensor
^ Throttle Position Sensor (TPS) Sensor
^ Idle Air Control (IAC) Motor
10. Install throttle cable bracket.
11. Install throttle and speed control cables to bracket and throttle arm.
12. Connect negative cable to battery remote jumper terminal.