Upper Intake Manifold

REMOVAL

1. Disconnect electrical connectors at Air Bypass Valve, Throttle Position Sensor and EGR Position Sensor.
2. Disconnect throttle linkage at throttle ball and transmission linkage from throttle body. Remove two bolts securing bracket to intake manifold and position bracket with cables out of the way.
3. Disconnect upper intake manifold vacuum fitting connections by disconnecting all vacuum lines to vacuum tree, vacuum lines to EGR valve, and vacuum line to Fuel Pressure Regulator.
4. Disconnect PCV system by disconnecting hose from fitting on rear of upper manifold.
5. Remove nut retaining EGR Transducer to upper intake manifold.
6. Loosen EGR tube at exhaust manifold and disconnect at EGR Valve. Remove two bolts from EGR Valve to upper intake manifold and remove EGR Valve and Transducer as an assembly.
7. Remove two canister purge lines from fitting on throttle body.
8. Remove six upper intake manifold retaining bolts.
9. Remove two retaining bolts at front and rear edges of upper intake manifold where manifold support brackets are located.
10. Remove nut retaining alternator bracket to upper intake manifold and two bolts retaining alternator bracket to water pump and alternator.
11. Remove upper intake and throttle body as an assembly from lower intake manifold.

INSTALLATION

Upper Intake Manifold:

NOTE: Clean and inspect the mounting faces of the lower and upper intake manifolds before installing.

1. Position a NEW upper intake manifold gasket on top of the lower intake manifold.
2. Apply a coat of pipe sealant with Teflon (D8AZ-19554-A, or equivalent) to the threads.
3. Install the bolts and studs in their original locations.





4. Tighten in sequence in three (3) steps starting with the four center bolts to the following specifications.
a. 10 N-m (8 lb.ft.)
b. 20 N-m (15 lb.ft.)
c. 32 N-m (24 lb.ft.)
5. Position alternator bracket and install two retaining bolts to water pump and alternator. Install alternator bracket to upper intake manifold and tighten nut to 19 lb. ft. (25 N-m).
6. Connect EGR Valve to EGR tube making sure tube is properly seated in EGR Valve. Connect EGR Valve to upper intake manifold and install bolts. Tighten to 19 lb. ft. (25 N-m).
7. Install canister purge lines to fittings on throttle body.
8. Connect PCV hose to rear of upper intake manifold.
9. Connect vacuum hoses to vacuum tree, EGR Valve and Fuel Pressure Regulator.
10. Position throttle linkage bracket with cables to upper intake manifold. Install two retaining bolts and tighten to 13 lb. ft. (17 N-m). Connect throttle cable and AXOD transmission cable cable to throttle body.
11. Connect electrical connectors at Air Bypass Valve, Throttle Position Sensor, and EGR Position Sensor.

NOTE: If lower intake manifold was removed, fill and bleed cooling system.