Upper Intake Manifold New

Upper Intake Manifold and Throttle Body:

REMOVAL

1. Disconnect throttle linkage at throttle ball and automatic transmission linkage from throttle body. Remove two bolts securing bracket to intake and position bracket with cables out of the way.
2. Remove two canister purge lines from fittings on throttle body.
3. Disconnect electrical connectors at:
a. throttle air bypass valve
b. throttle position sensor
c. EGR position sensor.
4. Disconnect upper intake manifold vacuum fitting connections by disconnection:
a. vacuum line to MAP sensor
b. vacuum line to EGR valve
c. vacuum line to fuel pressure regulator.
5. Disconnect EGR and PCV systems by disconnecting:
a. EGR valve flange nut
b. PCV hose at rear of upper manifold.

Upper Intake Manifold and Throttle Body:

6. Disconnect water heater lines from throttle body.

Upper Intake Manifold:

7. Remove four upper intake manifold retaining bolts.
8. Remove upper intake manifold and throttle body as an assembly.






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 ensuring gasket remains in place (if alignment studs are not used).
4. Install four upper intake manifold retaining bolts. Tighten to 16-24 Nm (12-18 ft-lbs).
5. Install EGR tube.
6. Connect water heater lines to the throttle body.
7. Connect PCV hose to rear of upper manifold.
8. Connect vacuum lines to MAP sensor, EGR valve, and fuel pressure regulator.
9. Position throttle linkage bracket with cables to upper intake manifold. Install two attaching bolts and tighten to specification. Connect throttle cable and AOD transmission cable to throttle body. Refer to specifications.
10. Connect electrical connectors at air bypass valve, TP sensor, and EGR position sensor.
NOTE: If lower intake manifold was removed, fill and bleed cooling system.