Electronic Fuel Injection - EFI

Air Cleaner Assembly:

REMOVAL

1. Disconnect the negative battery cable. Relieve the fuel system pressure, see MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
2. Remove accelerator cable and speed control cable.
3. Disconnect the top manifold vacuum fitting connections by disconnecting:
a. Rear vacuum line to the dash panel vacuum tree.
b. Vacuum line at the intake manifold.
c. MAP sensor vacuum line.
d. Fuel pressure regulator vacuum line.
4. Disconnect the PCV system by disconnecting the hoses from the PCV valve at the intake manifold connection.
5. Disconnect the EGR vacuum line at the EGR valve and EGR tube.
6. Disconnect the EGR tube from the upper intake manifold by supporting the connector while loosening the compression nut.

EGR Mounting Flange:

Upper Intake Manifold Support Bracket:

7. Remove manifold upper support bracket top bolt.
8. Disconnect the electrical connectors at the main engine harness.
9. Remove the fuel supply and return lines.
10. Remove the eight manifold mounting bolts.
11. Disconnect the lower support manifold bracket by removing the top bolt only. Leave the bottom bolts attached.
12. Remove the manifold with the wiring harness and gasket.

INSTALLATION:


1. Ensure that gasket surfaces of upper and lower intake manifolds are clean.
2. Place a new gasket on lower manifold assembly and mount upper intake manifold to lower, securing it with five retaining bolts. Tighten bolts to 15-22 lb. ft. (20-30 N-m).
3. Reconnect manifold upper support bracket. Tighten bolts to 15-22 lb. ft. (20-30 N-m).
4. Reconnect EGR tube with oil coated compression nut. Tighten to 29-40 lb. ft. (40-55 N-m).
5. Install PCV system. Connect the large PCV vacuum line to the upper manifold fitting.
6. Connect the rear manifold vacuum connections at the dash panel vacuum tree and connect the vacuum lines to the upper manifold.
7. Connect the accelerator and speed control cables.
8. Connect the wiring harness at the engine control harness.
9. Connect the fuel supply and return lines.
10. Install the spring lock couplings.
11. Connect the negative battery cable.
12. START the engine and check for fuel leaks.