Upper Intake Manifold

REMOVAL





Fig. 36

1. Disconnect negative cable from auxiliary jumper terminal (Fiat 36).





Fig. 37

2. Remove bolt holding air inlet resonator to intake manifold (Fig. 37).
3. Loosen throttle body air inlet hose clamp.
4. Release snaps holding air cleaner housing cover to housing.
5. Remove air cleaner cover and inlet hoses from





Fig. 38

6. Disconnect connectors from MAP and intake air temperature sensors (Fig. 38).
7. Remove manifold support bracket bolt located rearward of MAP sensor (Fig. 38).





Fig. 39





Fig. 40

8. Disconnect TPS and idle air control motor connectors (Fig. 39) and (Fig. 40).
9. Disconnect brake booster hose.
10. Disconnect curve hose from throttle body.





Fig. 41

11. Squeeze retainer tab on throttle cable and slide cable out of bracket (Fig. 41).
12. Slide speed control cable out of bracket, if equipped (Fig. 41).





Fig. 42

13. Remove EGR tube from intake manifold and discard gasket (Fig. 42).
13. Remove manifold support bracket bolt located rearward of EGR tube (Fig. 42).





Fig. 43

15. Remove bolts holding upper intake manifold and remove manifold (Fig. 43).

INSTALLATION
1. Install new gasket and position upper intake manifold to lower manifold. Install manifold bolts and tighten to 18 Nm (13 ft. lbs.) (Fig. 43).
2. Install bolts at manifold support brackets. Tighten bolts to 18 Nm (13 ft. lbs.).
3. Install EGR tube with new gasket to plenum. Tighten EGR tube to intake manifold plenum screws to 11 Nm (95 in. lbs.).
4. Install throttle and speed control cables.
5. Connect brake booster hose.
6. Connect purge hose to throttle body.
7. Attach electrical connectors to sensors.
8. Install air cleaner cover and inlet hoses.
9. Tighten air inlet tube clamps to 3 Nm +1 (25 in. lbs. +5).
10. Install bolt holding air inlet resonator to intake manifold (Fig. 37).
11. Connect negative cable to auxiliary jumper terminal (Fig. 36).