Upper Intake Manifold

Removal
1. Disconnect battery ground cable.
2. Remove cowl vent screen and windshield wiper.
3. Remove air cleaner outlet tube.
4. Remove accelerator cable shield.
5. Remove accelerator cable, accelerator spring and speed control actuator cable from throttle body lever. Remove accelerator spring from vehicle.
6. Remove accelerator cable bracket from throttle body (position aside).
7. Disconnect engine control sensor wiring from Throttle Position Sensor (TP sensor), and Idle Air Control Valve (IAC valve).
8. Remove evaporative emission hose from upper intake manifold.





9. Remove crankcase vent connector and hose from upper intake manifold to Positive Crankcase Ventilation Valve (PCV valve) at upper intake manifold.
10. Disconnect main emission vacuum control connector from the upper intake manifold.
11. Remove EGR valve.

12. CAUTION: When removing engine components, always remove retaining bolts in reverse of tightening sequence (as shown) or damage to engine components may occur.





Remove intake manifold retaining bolts the sequence shown.
13. Remove upper intake manifold and intake manifold upper gaskets from lower intake manifold and discard intake manifold upper gaskets.

Installation
1. Follow removal procedure in reverse order using new intake manifold upper gaskets.

(Part 1 Of 2):

(Part 2 Of 2):

2. Tighten upper intake manifold retaining bolts in sequence shown to 8-12 Nm (71-106 inch lbs.). Tighten accelerator cable bracket retaining bolts to 8-12 Nm (71-106 inch lbs.) Tighten EGR valve to exhaust manifold tube nut to 35-45 Nm (26-33 ft. lbs.).