Upper Intake Manifold

INTAKE MANIFOLD UPPER

REMOVAL
1. Disconnect negative cable from remote jumper terminal.





2. Disconnect the Inlet Air Temperature (IAT) Sensor connector. Remove air cleaner housing and inlet hose (Fig. 121).
3. Remove throttle and speed control cables from throttle arm and bracket.
4. Disconnect electrical connectors from the following sensors and actuators:
- Short Runner Valve (SRV) (If Equipped)
- Manifold Tuning Valve (MTV) (If Equipped)
- Throttle Position Sensor (TPS)
- Idle Air Control (IAC)
- Manifold Absolute Pressure (MAP)
5. Disconnect vacuum hoses from the following:
- Speed Control Reservoir
- Positive Crankcase Ventilation (PCV) Valve
- Proportional Purge Solenoid
- Power Brake Booster








6. Remove right side (Fig. 122) and left side (Fig. 123) intake manifold supports.





7. Remove support brackets at intake manifold front corners and at MTV (Fig. 124).
8. Loosen upper fastener attaching throttle body to support bracket.





9. Remove bolts attaching intake manifold and remove manifold (Fig. 125).

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.

INSTALLATION
1. Clean and inspect gasket sealing surfaces.

NOTE: Intake gaskets can be reused, provided they are free of cuts or tears.

2. Inspect gasket for cuts or tears. Replace gaskets as necessary.
3. Install intake manifold (Fig. 125) and hand start all attaching bolts.

Upper:

4. Tighten bolts gradually in sequence shown in (Fig. 126)until a torque of 12 Nm (105 in. lbs.) is obtained.
5. Install right side (Fig. 122) and left side (Fig. 123) intake manifold supports.
6. Install manifold support brackets at front corners and at MTV (Fig. 124).
7. Tighten fastener attaching throttle body to support bracket.
8. Connect vacuum lines to the following:
- Speed Control Reservoir
- Positive Crankcase Ventilation (PCV) Valve
- Proportional Purge Solenoid
- Power Brake Booster
9. Connect electrical connectors to the following:
- Short Runner Valve (SRV)(If Equipped)
- Manifold Tuning Valve (MTV) (If Equipped)
- Throttle Position Sensor (TPS)
- Idle Air Control (IAC)
- Manifold Absolute Pressure (MAP)
10. Install throttle and speed control cables to bracket and throttle arm.
11. Install air cleaner housing and inlet hose (Fig. 121). Connect Inlet Air Temperature (IAT) Sensor connector.
12. Connect negative cable to remote jumper terminal.