Upper Intake Manifold

Pre-Service Procedures
The fuel charging assembly consists of the air throttle body, and the upper and lower intake manifolds. Prior to service or removal of the fuel charging assembly, the following steps must be taken:
1. Open hood and install protective covers.
2. Disconnect negative battery lead and secure it out of the way.
3. Remove fuel cap at tank pressure.
4. Release pressure from fuel system.

Removal
1. Disconnect electrical connectors at air bypass valve, Throttle Position Sensor (TPS) and Exhaust Gas Recirculation (EGR) Position Sensor.
2. Disconnect throttle linkage at throttle ball and Automatic Overdrive (AOD) transmission linkage from throttle body. Remove two bolts securing bracket to intake and position bracket with cables out of 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 Positive Crankcase Ventilation (PCV) system by disconnecting hose from fitting on rear of upper manifold.
5. Remove two canister purge lines from fittings on throttle body.
6. Disconnect EGR tube from EGR valve by removing flange nut.
7. Remove bolt from upper intake support bracket to upper manifold.
8. Remove six upper intake manifold retaining bolts.
9. Remove upper intake and throttle body as an assembly from lower intake manifold.





Installation
1. Clean and inspect the mounting faces of the tower 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 making sure gasket remains in place (if alignment studs aren't used).
4. Install six upper intake manifold retaining bolts and tighten to 17-24 N-m (12-18 ft-lbs).
5. Install upper intake support bracket-to-upper manifold attaching bolt.
6. Install EGR tube.
7. Install canister purge lines to fittings on throttle body.
8. Connect PCV hose to rear of upper manifold.
9. Connect vacuum lines to vacuum tree, EGR valve, and fuel pressure regulator.
10. 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.
11. Connect electrical connectors at air bypass valve, TPS, and EGR position sensor.

NOTE: If lower intake manifold was removed, fill and bleed cooling system.

Post-Service Procedures
After the service is complete and the fuel charging assembly is installed to engine, the following steps must be taken:
1. Install fuel cap at tank.
2. Connect negative battery lead.
3. Turn Key ON/OFF several times without starting engine to, check for fuel leaks.

NOTE: Check all connections at fuel rails, push connect fittings, etc.

CAUTION: The fuel system is normally pressurized to 276 kPa (40 psi).

4. Start engine and warm to operating temperature. Check for coolant leak if coolant was removed.
5. Perform Electronic Engine Control (EEC-IV) Self Test to check systems function.