Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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REMOVAL- UPPER 1. Disconnect negative cable from battery remote jumper terminal. 2. Disconnect Inlet Air Temperature (IAT) Sensor connector. Remove air inlet resonator and inlet tube. 3. Remove throttle cable and speed control cable from throttle arm and bracket. 4. Remove throttle cable bracket. 5. Disconnect electrical connectors from the following components: – Manifold Absolute Pressure (MAP) Sensor – Throttle Position Sensor (TPS) Sensor – Idle Air Control (IAC) Motor 6. Disconnect Vapor Purge hose, Brake Booster hose, Speed Control Servo, Positive Crankcase Ventilation (PCV) hose (Fig. 104). 7. Loosen upper fastener at throttle body support bracket 9. Remove upper manifold (Fig. 105). 10. Inspect manifold. INSPECTION Check manifold for: – Damage and cracks – Gasket surface damage or warpage – Damaged or clogged EGR ports

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2. Note position of spark plug wires, and disconnect from ignition coils. Remove throttle cable bracket with cables. Remove EVAP canister purge solenoid. Disconnect Throttle Position (TP) and Idle Air Control (IAC) sensors. Disconnect injector harness. Disconnect Engine Coolant Temperature (ECT) sensor. 3. Disconnect Camshaft Position (CMP) sensor and vacuum modulator. Remove MAP sensor vacuum line. Remove bolts and MAP sensor. Remove EGR pipe. Remove inlet and outlet hoses from throttle body. Remove upper intake manifold bolts. Remove upper intake manifold and gaskets. Installation Clean gasket surfaces. Install NEW gaskets onto cylinder heads. Ensure all holes are aligned. For correct installation, observe reference marks on gaskets (if present). Install upper intake manifold. See Fig. 1. Using crisscross pattern, tighten bolts to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING.

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Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414-00. 2. Remove the parts in the order indicated in the following illustration and table. Item Part Number 1 14A464 2 14489 3 9F715 4 N806549-S 5 9J558 3. To install, reverse the removal procedure. Item 3: IMRC Actuator Rods Installation Note 1. New plastic actuator rod retainers must be installed any time the IMRC rods are disconnected. Item 5: IMRC Actuator Installation Note 1. Before installing the IMRC actuator, be sure to rotate the driver motor plate until the levers make contact with the set screws, then rotate the motor until the motor bracket bolt holes are aligned with the holes in the lower intake manifold. Description Camshaft position (CMP) sensor electrical connector (part of 12B637) Intake manifold runner control (IMRC) actuator electrical connector (part of 12B637) IMRC actuator rods (2 req’d) (part of 9J559) Installation Note IMRC actuator-to-intake manifold bolts (3 req’d) IMRC actuator Installation Note

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1. NOTE: When the battery has been disconnected or reconnected, volatile memory information will be lost. The affected systems will have to be programmed by the technician or customer. These systems include: radio station presets, clock settings, seat memory, mirror memory, window memory and customer input keyless, window memory and customer input keyless entry codes. Disconnect the battery ground cable. For additional information, refer to Section 14-01. 2. Drain the cooling system. For additional information, refer to section 03-03. 3. Remove the engine cover (covering the throttle body). 4. Disconnect the crankcase ventilation tube and the idle air control valve inlet tube from the air cleaner outlet tube. Remove the air cleaner outlet tube. 5. WARNING: THE FUEL SUPPLY LINES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES REMAIN PRESSURIZED FOR LONG PERIODS AFTER ENGINE SHUT DOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE, TO PREVENT POSSIBLE INJURY. Connect the Multiport Fuel Injection (MFI) Fuel Pressure Gauge (T80L-9974-B) to the fuel pressure relief valve on the fuel supply manifold. Open the manual valve on the gauge to relieve the fuel system pressure. Once the pressure is relieved, close the valve and remove the gauge. 6. Remove the locking clip from the pressure and return fuel line spring lock couplings. Using the spring lock coupling disconnect tools (D87L-9280-A for 3/8-inch line, D87L-9280-B for 1/2-inch line) on the couplings. Push the tool into the cage opening to release the female fitting from the garter spring. Remove the tool and pull the male coupling and fitting apart. Install protective caps over the lines and the fuel rail. 7. Disconnect the upper radiator hose from the water outlet connection and position it out of the way. 8. Disconnect the accelerator cable and the speed control actuator cable from the throttle body and the locator. Remove the screws retaining the cables to the accelerator cable bracket and position the cables out of the way. 9. Disconnect the wiring connectors from the throttle position sensor (TP), idle air control valve (IAC) and the engine coolant temperature sensor (ECT). Disconnect the wiring connectors from the LH fuel injectors and the two wiring locators from the fuel rail. Position the harness out of the way. 10. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the LH spark plugs and position them out of the way. Refer to Section 03-07. 11. Remove the bolts retaining the spark plug wiring harness bracket to the intake manifold and the generator. Disconnect the ignition wires from the locators and remove the bracket. 12. Remove the serpentine drive belt from the generator pulley. Refer to Section 03-05. 13. Remove the generator retaining bolts and position it out of the way. 14. Remove the PCV valve and tube. 15. Disconnect the wiring connectors from the water temperature indicator sender unit and the EGR vacuum regulator solenoid. Disconnect the RH fuel injector connectors and harness locators from the fuel rail. Position the harness out of the way. 16. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the RH spark plugs and position them out of the way. For additional information, refer to Section 03-07. 17. Disconnect the vacuum line from the fuel vapor storage canister purge valve. Disconnect the heater hose from the rear of the intake manifold. 18. Disconnect the main vacuum hose from the rear of the intake manifold. Disconnect the hose from the fuel vapor storage canister purge valve. 19. Disconnect the EGR tube nut from the EGR valve. 20. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve and gasket. 21. Remvoe the water outlet connection housing. 22. Remove the intake manifold. Remove and discard the intake manifold gaskets.

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Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. All engines 1. Disconnect the battery ground cable (14301). For additional information, refer toSection 414-01. 2. Relieve the fuel pressure. For additional information, refer toSection 310-00A. 3. Partially drain the cooling system. For additional information, refer toSection 303-03A or Section 303-03B. 4. Remove the power steering reservoir bracket. 1. Remove the bolts. 2. Position the power steering reservoir bracket out of the way. 5. Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 6. Disconnect the fuel pressure regulator valve vacuum hose. 7. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. Disconnect the fuel lines. For additional information, refer toSection 310-00A. 8. Disconnect the eight ignition coil electrical connectors. 9. Disconnect the eight fuel injector electrical connectors. 4.6L engines 10. Remove the nut and disconnect the brake booster vacuum hose and bracket 5.4L engines 11. Remove the brake booster bracket and tube. 1. Remove the nut. 2. Release and move the two hose clamps. 3. Remove the brake booster tube. All engines 12. Remove the positive crankcase ventilation (PCV) hose. 5.4L engines 13. Disconnect the water heater inlet tube hose. 1. Release and move the hose clamp. 2. Disconnect the water heater inlet tube hose and position aside.