Upper Intake Manifold
UPPER INTAKE MANIFOLDREMOVAL
1. Disconnect negative battery cable.
2. Remove throttle body air inlet hose and air cleaner housing assembly.
3. Remove throttle cable shield. Remove throttle and speed control cables from throttle arm and bracket.
4. Remove throttle cable bracket.
5. Disconnect electrical connectors from the following components:
^ Manifold Absolute Pressure (MAP) 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. Loosen upper fastener at throttle body support bracket.
8. Remove manifold attaching bolts (Fig. 106).
9. Remove upper manifold (Fig. 105).
10. Inspect manifold.
INSPECTION
Check manifold for:
^ Damage and cracks
^ Gasket surface damage or warpage
^ Damaged or clogged EGR ports
If the manifold exhibits any damaged or warped conditions, replace the manifold. Clean EGR ports as necessary.
If a vacuum port is damaged, a repair procedure can be performed.
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. 105).
3. Install manifold attaching bolts and tighten in sequence shown in (Fig. 106) to 12 Nm (105 in. lbs.).
4. Tighten upper fastener at throttle body support bracket.
5. Connect speed control servo, PCV, brake booster, and vapor purge hoses.
6. Connect electrical connectors to the following components:
^ Manifold Absolute Pressure (MAP) Sensor
^ Throttle Position Sensor (TPS) Sensor
^ Idle Air Control (IAC) Motor
7. Install throttle cable bracket.
8. Connect throttle and speed control cables to bracket and throttle arm. Install throttle cable shield.
9. Install throttle body air inlet hose and air cleaner housing assembly.
10. Connect negative battery cable.