Upper Manifold Assembly

Removal Procedure
1. Remove the negative battery cable.
2. Remove the air intake duct.
3. Remove the accelerator cable splash shield from accelerator cable bracket.
4. Remove the accelerator, cruise, and transmission control cables.
5. Remove the vacuum hose harness from top of air inlet.
6. Disconnect crankcase ventilation valve and power brake vacuum hoses from vacuum tubes at upper manifold (position vacuum hoses out of the way).
7. Remove the electrical connectors at MAP sensor, TP sensor, and IAC valve.
8. Remove the bolts/nuts attaching accelerator cable bracket (position bracket and cables out of the way).
9. Remove the MAP sensor.
10. Remove the bolts/studs (1) attaching upper manifold to lower manifold (position fuel injector wiring harness out of the way).
11. Remove the upper manifold assembly (2) and gasket (3) (discard gasket).

Notice: In order to prevent damage to the sealing surfaces, carefully use sharp tools in cleaning the old gasket from the aluminum surfaces.

12. Clean gasket mating surfaces.
13. Inspect the replacement upper manifold for items that are to be transferred to the new manifold.
14. Disassemble the upper manifold following component repair procedures.
15. Assemble the replacement upper manifold with transferred parts following component repair procedures.


Installation Procedure

Notice: The EVAP canister may have released carbon particles which may have caused this parts failure. Check the EVAP canister for carbon before returning to the vehicle to service.

1. Install the new upper manifold gasket (3).
2. Install the upper manifold assembly (2) (reposition injector wiring harness).
3. Install the upper manifold attaching bolts/studs (1).






4. Tighten the upper manifold bolts/studs to the tightening sequence shown. Tighten the upper manifold bolts/studs to 30 Nm (22 lb. ft.). Refer to second image for tightening sequence.
5. Install the MAP sensor.
6. Install the accelerator cable bracket with attaching bolt/nuts.
^ Tighten the accelerator cable bracket nuts to 30 Nm (22 lb, ft.).
^ Tighten the accelerator cable bracket bolts to 25 Nm (18 lb. ft.).
7. Install the accelerator, cruise, and transmission control cables.
8. Install the splash shield to accelerator bracket. Tighten the accelerator cable splash shield screws to 1.9 Nm (17 lb. in.).
9. Install the electrical connectors to MAP sensor, TP sensor, IAC valve, and EGR vacuum solenoid.
10. Install the vacuum hose harness to top of air inlet.
11. Connect crankcase ventilation valve and power brake vacuum hoses to vacuum tubes at upper manifold.
12. Install the air intake duct.
13. Install the negative battery cable.