Upper

UPPER INTAKE MANIFOLD

Non-Turbo










1. If lower intake manifold was covered during service, remove cover (1).
2. Clean all sealing surfaces. Replace seals as necessary.
3. Position new seals on manifold.





4. Position upper intake manifold on lower intake manifold. Tighten upper intake manifold fasteners to 12 Nm (105 in. lbs.) in sequence shown.





5. Connect PCV hose (2) to intake manifold.










6. Connect manifold absolute pressure (MAP) (1) electrical connector.










7. Connect proportional purge hoses (1).





8. Connect brake booster hose.
9. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.





10. Install throttle and speed control cables to bracket. Connect cables to the throttle lever.
11. Connect negative cable to battery.










12. Install air cleaner housing (1) and clean air hose. Tighten clean air hose clamp to 1.7 Nm (15 in. lbs.).
13. Connect make-up (3) air hose and inlet air temperature sensor (2).

Turbo










1. If lower intake manifold was covered during service, remove cover (1).
2. Clean all sealing surfaces. Replace upper intake manifold gasket.






NOTE: This engine could be equipped with either a plastic intake manifold or an aluminum intake manifold.

3. Position upper intake manifold on lower intake manifold. On engines equipped with an aluminum intake manifold, tighten manifold fasteners to 28 Nm (250 in. lbs.) in sequence shown. On engines equipped with a plastic intake manifold, tighten manifold fasteners to 12 Nm (105 in. lbs.) in sequence shown.





4. Install upper intake manifold to cylinder head support bracket (1). Torque cylinder head fasteners to 28 Nm (250 in. lbs.) and manifold fasteners to 6 Nm (55 in. lbs.).










5. Install the intake manifold cover (1).










6. Connect purge solenoid hose to throttle body (1).





7. Connect brake booster vacuum hose and PCV hose to intake manifold.
8. Install the 2 screws for the throttle cable bracket and tighten to 12 Nm (105 in. lbs.) on aluminum intake manifolds and 6 Nm (55 in. lbs.) on plastic intake manifolds.





9. Install the throttle control shield.
10. Connect idle air control (IAC) motor and throttle position sensor connectors.










11. Connect the MAP sensor (1) connector.










12. Connect charge air cooler hose to throttle body (1). Tighten hose clamp to 1.7 Nm (15 in. lbs.).
13. Connect negative battery cable.