Upper Intake Manifold Assembly Replacement
Upper And Lower Manifold Assemblies:
Upper And Lower Intake Manifold Part Names:
A label containing the last four digits of the upper manifold assembly identification number appears above the power brake fitting assembly. The bar code (read by an optical scanner) also contains the component number for manifolds, and the four digits of the identifying number. Refer to this number if servicing or part replacement is required.
Refer to the disassembled view for identification of parts during repair procedures.
Accelerator Cable Bracket:
Upper Manifold Assembly And Tightening Sequence:
Identification Tag:
Splash Shield:
Remove or Disconnect:
1. Negative battery cable.
2. Air intake duct.
3. Accelerator cable splash shield from accelerator cable bracket.
4. Accelerator, cruise and transmission control cables.
5. Vacuum hose harness from top of air inlet.
6. Disconnect PCV and power brake vacuum hoses from vacuum tubes at upper manifold. Position vacuum hoses out of the way.
7. Electrical connectors at MAP sensor, TP sensor, and IAC valve.
8. Bolts/nut attaching throttle cable bracket. Position bracket and cables out of the way.
9. Bolts/studs attaching upper manifold to lower manifold. Position EGR and injector wiring harness out of the way.
10. Upper manifold assembly and gasket.
^ Discard gasket.
NOTICE: Use care in cleaning old gasket material from machined aluminum surfaces as sharp tools may damage sealing surfaces.
^ Clean gasket surfaces.
Inspect
^ Replacement upper manifold for items that are to be transferred from unit removed from engine.
Disassemble
^ Upper manifold.
^ Power brake vacuum fitting.
Assemble:
^ Replacement upper manifold with transferred parts following component repair procedures.
^ Power brake vacuum fitting, coated with appropriate thread-locking material.
Tighten:
^ Vacuum fitting to 13.0 Nm (115 lb. in.).
Install or Connect:
^ Position EGR valve injector so that the port faces directly toward the throttle bore.
1. New upper manifold gasket.
2. Upper manifold assembly.
^ Reposition EGR and injector wiring harness.
3. Upper manifold attaching bolts/studs.
Tighten:
^ Upper manifold bolts/studs to 30.0 Nm (22 lb. ft.).
4. Accelerator cable bracket with attaching bolts/nut.
^ Accelerator cable bracket bolts to 25 Nm (18 lb. ft.)
^ Accelerator cable bracket nuts to 30 Nm (22 lb. ft.)
5. Accelerator, cruise, and transmission control cables.
6. Splash shield to accelerator bracket.
7. Electrical connectors to MAP sensor, TP sensor, IAC valve, and EGR vacuum solenoid valve.
8. Vacuum hose harness to top of air inlet.
9. Connect crankcase ventilation valve hose and power brake vacuum hoses to vacuum tubes at upper manifold.
Inspect:
^ Turn ignition switch to the 'ON" position for two seconds, then turn to the "OFF" position for ten seconds. Again turn to the "ON" position, and check for fuel leaks.
10. Negative battery cable.
11. Air intake duct.