Upper Manifold Assembly

Remove or Disconnect

1. Negative Battery cable.
2. Air intake duct.








3. Accelerator cable splash shield from accelerator cable bracket (see Figure 2).
4. Accelerator, cruise and transmission control cables.
5. Vacuum hose harness from top of air inlet.
6. Disconnect [1][2]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, TPS, and IAC valve (See Figure 3).

8. Bolts/nuts 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, do not attempt to re-use gasket.

NOTICE:
USE EXTREME CARE WHEN CLEANING OLD GASKET MATERIAL FROM MACHINED ALUMINUM SURFACES. SHARP TOOLS MAY DAMAGE SEALING SURFACES.

11. Clean all gasket sealing surfaces.

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 (See Figure 4)
* Reposition EGR and injector wiring harness.
3. Upper manifold attaching bolts/studs.
* Tighten upper manifold bolts/studs to 30.0 N-m (22 lbs.ft.).
4. Accelerator cable bracket with attaching bolts/nuts.
* Finger tighten only at this time.

NOTICE:
THE ACCELERATOR BRACKET MUST BE ALIGNED WITH THE ACCELERATOR CAM TO PREVENT CABLE WEAR, WHICH COULD RESULT IN CABLE BREAKAGE.

A. Place a steel rule across bore of throttle body, with one end in contact with accelerator bracket.





B. Adjust accelerator bracket to obtain a 10 mm +/- 1 mm (25/64 +/- 1/32) gap between bracket and throttle body (See Figure 5).
C. Tighten top bolt first.
D. Tighten accelerator cable bracket bolts/nuts to 25 N-m (18 lbs.ft.).
5. Accelerator, cruise and transmission control cables.
6. Splash shield to accelerator bracket.
7. Electrical connectors to MAP sensor, TPS, IAC valve and EGR vacuum solenoid.
8. Vacuum hose harness to top of air inlet.
9. Connect [1][2]PCV and power brake vacuum hoses to vacuum tubes at upper manifold.
10. Negative battery cable. 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.
11. Air intake duct.