Upper Intake Manifold

REMOVAL





1. Disconnect the battery ground cable.





2. Remove the water pump pulley shield.
1 Remove coolant recovery hose from clip.
2 Remove the four bolts.
3 Remove the water pump pulley shield.

3. Remove the Air Cleaner Housing and Air Cleaner Outlet tube.





4. On SVT equipped vehicles, disconnect the accelerator and speed control cables.
1 Unclip the cables from the bracket.
2 Disconnect the accelerator and speed control cables





5. On SVT equipped vehicles, remove the accelerator cable bracket and disconnect the EGR valve.
1 Remove the accelerator cable bracket bolts.
2 Remove the accelerator cable bracket.
3 Remove the EGR valve bolts and discard the gasket.





6. On non-SVT equipped vehicles, remove the accelerator bracket and the EGR Valve from the upper intake manifold.
1 Remove Accelerator bracket bolts.
2 Disconnect Accelerator and Speed Control Cables from the throttle body and position aside.
3 Remove EGR valve bolts and discard the gasket.





7. Disconnect the following vacuum hoses.
- Depress the black retainer and disconnect the two vacuum supply lines from the upper intake.
- Disconnect the EGR Vacuum Regulator (EVR) vacuum hose.





8. Disconnect the PCV hose and electrical connectors.
- Throttle Position (TP) sensor electrical connector.
- PCV hose.
- Idle Air Control (IAC) valve electrical connector.





9. Disconnect the EVR electrical connector.





10. Remove the bolts in the indicated sequence, remove the upper intake manifold and discard the gaskets.

INSTALLATION

NOTE:
- Verify the insulating bushings are on the bolts of the upper intake manifold.
- New gaskets must be used, position the gasket on the lower intake manifold.





1. Position the upper intake manifold and tighten the bolts in the indicated sequence.





2. Connect the EVR electrical connector.





3. Connect the PCV hose and electrical connectors.
- Throttle Position (TP) Sensor electrical connector.
- PCV hose.
- Idle Air Control (IAC) Valve electrical connector.





4. Connect the following vacuum hoses.
- Two vacuum supply hoses to the upper intake.
- EGR Vacuum Regulator (EVR) vacuum hose.

NOTE: Install a new EGR valve gasket prior to installation.





5. On non-SVT equipped vehicles, install the accelerator bracket and EGR valve to the upper intake manifold.
1 Position the accelerator bracket and install the bolts.
2 Connect the accelerator and speed control cables to the throttle body.
3 Position the EGR valve and the bolts.

NOTE: Use a new EGR gasket.





6. On SVT equipped vehicles, install the accelerator cable bracket and EGR valve bolts.
1 Position the accelerator cable bracket.
2 Install the accelerator cable bracket nut and bolts.
3 Position a new gasket and install the bolts





7. On SVT equipped vehicles, connect the accelerator and speed control cables.
1 Connect the accelerator and speed control cables.
2 Clip the cables into the bracket.





8. Install the water pump pulley cover.
1 Install the water pump pulley cover.
2 Install the bolts.
3 Position the coolant recovery hose in the clip.

9. Install the Air Cleaner Housing and Air Cleaner Outlet tube.

NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.





10. Connect battery ground cable.