Upper

1. Disconnect battery ground cable.
2. Remove water pump pulley shield bolts, then shield.
3. Press black retainer on upper intake manifold with screwdriver and disconnect main emission vacuum control connector and brake booster vacuum connector from manifold.
4. Loosen engine air cleaner tube clamps on air cleaner outlet tube.
5. Disconnect crankcase ventilation hoses and Idle Air Control (IAC) valve tube from outlet tube fitting.
6. Remove outlet tube from Mass Air Flow (MAF) sensor and throttle body.
7. Remove accelerator cable and speed control actuator from throttle body, then accelerator cable bracket from intake manifold. Position bracket aside.
8. Remove IAC valve fresh air supply hose from upper intake manifold fitting.
9. Disconnect fuel charging wiring from Throttle Position (TP) sensor, IAC valve and EGR vacuum regulator control.
10. Remove vacuum supply hose from upper intake manifold to Positive Crankcase Ventilation (PCV) valve at upper intake manifold, then disconnect vacuum supply hoses to EGR vacuum regulator control and EGR valve.
12. Loosen and remove EGR valve to exhaust manifold tube nut from EGR valve, then position tube aside.

Fig. 4 Upper intake manifold bolt removal sequence:

13. Remove intake manifold bolts in sequence. When removing engine components, always remove bolts in reverse order of tightening sequence or damage to engine components may occur.
14. Remove upper intake manifold and lower intake manifold upper gaskets. Discard intake manifold upper gaskets.
15. Reverse procedure to install, noting following:
a. Install new intake manifold upper gaskets.

Fig. 4 Upper intake manifold bolt tightening sequence:

b. Torque intake manifold bolts in sequence to 5.9-8.8 ft lb.