Electronic Fuel Injection - EFI

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 tube at PCV valve. Disconnect wire at EGR Transducer.
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 alternator brace by removing nut from brace to upper intake manifold and by removing two bolts at alternator and water pump.
9. Remove six upper intake manifold retaining bolts. Remove one bolt at front and rear of upper intake manifold where manifold support brackets are located.
10. Remove upper intake and throttle body as an assembly from lower intake manifold.

INSTALLATION

Upper Intake Manifold Removal/Installation:

1. Clean and inspect the mounting faces of the lower and upper intake manifolds.
2. Position new gasket on lower intake mounting face. The use of alignment studs may be helpful.
3. Install upper intake manifold and throttle body assembly to lower manifold.
4. Install four center bolts on top of manifold and tighten to 8 lb. ft. (10 N-m). Install two outside bolts on top of manifold and tighten to 8 lb. ft. (10 N-m). Repeat sequence in two steps: 15 lb. ft. (20 N-m) and 24 lb. ft. (32 N-m). Install two bolts through manifold support brackets at front and rear of manifold and tighten to 19 lb. ft. (25 N-m).
5. Position alternator brace and install bolt at alternator. Tighten to 37 lb. ft. (51 N-m). Install bolt at water pump and tighten to 19 lb. ft. (25 N-m).
6. Connect EGR Valve to EGR tube, making sure tube is pushed properly onto EGR Valve. Hand tighten.
7. Connect EGR Valve to upper intake manifold and install bolts. Tighten to 19 lb. ft. (25 N-m).
8. Tighten EGR tube at EGR Valve and exhaust manifold to 30 lb. ft. (41 N-m).
9. Install canister purge lines to fittings on throttle body.
10. Connect EGR Transducer to upper intake manifold and install nut. Tighten to 19 lb. ft. (25 N-m). Ensure EGR Transducer is connected to EGR Valve. Connect wire to EGR Transducer.
11. Connect PCV tube to PCV Valve.
12. Connect Fuel Pressure Regulator vacuum line to upper intake manifold.
13. Connect chassis vacuum tube to upper intake manifold. Connect remaining vacuum lines to EGR Valve and chassis vacuum tube.
14. Position throttle cable bracket and install two bolts. Tighten to 13 lb. ft. (17 N-m). Connect throttle cable and TV cable to throttle body.
15. 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.