Intake Manifold, Upper

Removal

1. Disconnect the electrical connectors at the following locations:

   • EGR external pressure valve (9F483)
   • throttle position sensor (TP sensor) (9B989)
   • idle air control valve (IAC valve) (9F715)
   • EGR transducer (9J433)

2. Disconnect the following vacuum connections:

   • vacuum line at the EGR external pressure valve
   • evaporative emission (EVAP) system lines to the throttle body (9E926) and evaporative emission canister purge valve (EVAP canister purge valve) (9C915)
   • vacuum lines to the upper intake manifold vacuum outlet fitting and cap (9A474) vacuum tree (labeling the hose locations with tape is recommended to aid installation)

   

   Item	Part Number	Description
   1	—	EGR Hoses (Part of 9D477)
   2	9J433	EGR Transducer
   3	390657-S2	Bolt, 5/16-18 x 1.12
   4	—	EGR Transducer Bracket
   5	9424	Intake Manifold (Upper)
   6	9D477	EGR Valve to Exhaust Manifold Tube
   A	—	Tighten to 16-24 Nm (12-18 Lb-Ft)

3. Tag EGR transducer hoses. Remove two screws, EGR transducer and bracket. Disconnect hoses.

4. Disconnect the PCV hose from the fitting, located on the underside of the upper intake manifold (9424).

5.  CAUTION: When disconnecting throttle cable from ball stud, use a screwdriver or similar tool close to the ball stud to pry off. Removing by hand may damage the cable.

   Remove the accelerator control splash shield (9E766), and disconnect the accelerator cable (9A758) and speed control actuator cable (9A825). Position the cable away from the engine.

6. Disconnect the air cleaner outlet tube (9B659) from the throttle body.

7. Disconnect the EGR valve to exhaust manifold tube (9D477) from the EGR external pressure valve and the rear exhaust manifold (9430). Remove the EGR valve to exhaust manifold tube from the engine (6007).

   EGR System

   

   Item	Part Number	Description
   1	9F483	EGR External Pressure Valve
   2	—	Connector (Part of 9D477)
   3	9424	Intake Manifold (Upper)
   4	9430	Exhaust Manifold (Rear)
   5	9D477	EGR Valve to Exhaust Manifold Tube
   6	390657-S2	Bolt
   7	9E494	Delta PFE Transducer
   A	—	Tighten to 34-47 Nm (25-35 Lb-Ft)
   B	—	Tighten to 16-24 Nm (12-18 Lb-Ft)

8. Remove the screw and washer assembly attaching the intake manifold support (9J444) to the upper intake manifold.

9. Remove the seven studs that retain the upper intake manifold.

   

   Item	Part Number	Description
   1	—	Delta PFE Transducer and HO2S Connector (Part of 9D930)
   2	9424	Intake Manifold (Upper)
   3	9H486	Intake Manifold Upper Gasket
   4	390715	Stud
   5	9D446	Vacuum Fitting
   6	9424	Intake Manifold (Lower)
   7	390659	PCV Connector
   A	—	Tighten to 16-24 Nm (12-18 Lb-Ft)
   B	—	Tighten to 8-13 Nm (6-10 Lb-Ft), Then Advance to Position Shown in View A

10. Remove the upper intake manifold and throttle body from the lower intake manifold.

Installation

1. Position a new intake manifold upper gasket (9H486) on the lower intake manifold, using the lower manifold dowels to position the intake manifold upper gasket.

2. Position the upper intake manifold onto the lower intake manifold, using the dowels of the lower intake to locate manifold holes. Install the seven studs to attach the upper intake manifold to the lower intake manifold and hand-tighten.

3. Tighten the seven studs attaching the upper intake manifold to the lower intake manifold to 16-24 Nm (12-18 lb-ft).

4. Position the upper intake manifold support onto the boss of the upper intake manifold, located under the throttle body. Install the retaining screw and tighten to 30-43 Nm (22-32 lb-ft).

5. Install the EGR valve to exhaust manifold tube between the EGR external pressure valve and the rear exhaust manifold. The tube is routed between lower intake runners No. 5 and No 6. Tighten both fittings to 34-47 Nm (25-35 lb-ft).

6. Connect the PCV hose to the fitting, located on the valve cover (6582) under the upper intake manifold.

7. Connect accelerator cable, transmission kickdown cable, and speed control actuator cable. Install accelerator control splash shield.

8. Connect the air cleaner outlet tube to the throttle body.

9. Install EGR transducer and bracket. Tighten screws to 17-24 Nm (12-18 lb-ft). Connect EGR transducer hoses.

   

   Item	Part Number	Description
   1	—	EGR Hoses (Part of 9D477)
   2	9J433	EGR Transducer
   3	390657-S2	Bolt 5/16-18 x 1.12
   4	—	EGR Transducer Bracket
   5	9424	Intake Manifold (Upper)
   6	9D477	EGR Valve to Exhaust Manifold Tube
   A	—	Tighten to 17-24 Nm (12-18 Lb-Ft)

10. Connect the following vacuum connections:

    • vacuum line to the EGR external pressure valve
    • evaporate Emission (EVAP)system lines to throttle body
    • vacuum lines to the upper intake manifold vacuum outlet fitting and cap vacuum tree

11. Connect the following electrical connectors at:

    • throttle position sensor
    • idle air control valve
    • EGR external pressure valve
    • evaporative emission canister purge valve