Upper Intake Manifold

REMOVAL

1. Disconnect battery ground cable.
2. On vehicles equipped with automatic transmission, disconnect kickdown cable from throttle linkage.
3. On all vehicles, disconnect accelerator cable from throttle linkage.
4. Remove accelerator cable bracket attaching screws and the bracket from upper intake manifold, position bracket, accelerator cable and kickdown cable, if equipped, out of way.
5. Disconnect fuel pressure regulator vacuum hose, PCV hose and the vacuum tree supply hose at intake manifold fittings.
6. Loosen hose clamps and remove turbocharger outlet hose.
7. Remove EGR flange attaching bolts.
8. Remove nut attaching pulse damper to bracket.
9. Disconnect low oil level sensor connector, then remove oil dipstick.
10. Remove oil dipstick bracket attaching screw.
11. Cut fuel injector wiring harness routing strap at pulse damper bracket as necessary.
12. Remove two pulse damper bracket attaching nuts and the bracket.
13. Remove two upper attaching screws and two lower attaching nuts connecting throttle body assembly to upper intake manifold.
14. Remove upper intake manifold attaching bolts, the manifold and gaskets.

Fig. 10 Upper Intake Manifold Bolt Tightening Sequence:

INSTALLATION

1. Ensure both gasket surfaces on upper intake manifold and upper surface of lower intake manifold are clean.
2. Place new gasket on lower intake manifold and place upper intake manifold in position, then install four attaching bolts, torquing to specification in proper sequence, Fig. 10.
3. Install two EGR flange attaching bolts and torque to specifications.
4. Place pulse damper bracket on upper intake manifold and install attaching nuts.
5. Install new fuel injection wiring harness routing strap as necessary.
6. Install oil dipstick bracket attaching screw.
7. Install oil dipstick and connect low oil level sensor connector.
8. Place pulse damper on bracket and install attaching nut.
9. Install new gasket and the throttle body attaching screws and nuts, torquing to specifications.
10. Connect vacuum tree source hose and PCV hose to fitting on upper intake manifold.
11. Connect fuel pressure regulator vacuum hose to fuel pressure regulator and the fittings on upper intake manifold.
12. Place accelerator cable bracket against upper intake manifold and install attaching screws.
13. Connect accelerator cable.
14. Connect kickdown cable, if equipped.
15. Install turbocharger outlet hose and tighten clamp.