Upper Intake Manifold

Removal
1. Remove the Air Cleaner (ACL).
2. Disconnect the battery ground cable.





3. Remove the water pump pulley shield.
1 Remove coolant expansion tank hose from clip.
2 Remove the bolts.
3 Remove the water pump pulley shield.





4. Remove the accelerator bracket and the EGR valve from the upper intake manifold.
1 Remove the bolts.
2 Disconnect accelerator and speed control cables from the throttle body and position to one side.
3 Remove the bolts and discard the gasket.





5. Disconnect the following vacuum hoses.
^ Depress the black retainer and disconnect the two vacuum supply lines from the upper intake.
^ Disconnect the vacuum regulator solenoid vacuum hose.





6. Disconnect the Position Crankcase Ventilation (PCV) hose and electrical connectors.
^ Throttle Position (TP) sensor electrical connector.
^ PCV hose.
^ Idle Air Control (IAC) valve electrical connector.





7. Disconnect the EGR vacuum regulator solenoid electrical connector.





8. NOTE: 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.





1. NOTE: New gaskets must be used, position the gasket on the lower intake manifold.

NOTE: Tighten the bolts in the indicated sequence.

Position the upper intake manifold and tighten the bolts.





2. Connect the EGR vacuum regulator solenoid electrical connector.





3. Connect the PCV hose and electrical connectors.
^ TP sensor electrical connector.
^ PCV hose.
^ IAC valve electrical connector.





4. Connect the following vacuum hoses.
^ Two vacuum supply hoses to the intake manifold upper.
^ EGR vacuum regulator solenoid vacuum hose.





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

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.





6. 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.
7. Install the Air Cleaner (ACL).

8. NOTE: When the battery has been 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 miles) or more to relearn the strategy.

Connect battery ground cable.